1. automotive and vehicles
2. cars
3. hybrid

2015
Formula Hybrid™
Rules
(Revision 2 – 10/15/2014)
The Formula Hybrid trademark is owned by the Trustees of Dartmouth College
Preface
Welcome to the 2015 edition of the Formula Hybrid rules.
You will find many changes in these rules. Most of these changes were made to increase the percentage of vehicles that
arrive at the competition ready to pass tech inspection and compete in all the events.
NEW! Project Management Component
Formula Hybrid is universally recognized as the most difficult and challenging of all the SAE CDS competitions. Many
new student teams become aware of the magnitude of this challenge late in the program, and find themselves unable to
bring their projects to completion in time for the competition.
This results in withdrawals, or arriving at the competition with an incomplete vehicle.
Utilizing project management techniques effectively in a complex project such as Formula Hybrid will guide the team to
a successful completion within the established deadline.
The new Project Management component replaces the Marketing presentation, and requires two additional submissions
during the year, as well as a presentation before a review board at the competition. . The first submission is due in
December immediately following the close of registration.
We have added an introductory tutorial in Appendix K, “Application of the Project Management Method to Formula
Hybrid” authored by Dr. Ed March, acting co-director of the Master of Engineering Management (MEM) program at
Dartmouth.
We cannot stress strongly enough the importance of each student team reading this document and applying the methods
described. We can state with a great deal of confidence that those teams that utilize a structured project management
process will score better at the competition than those that don’t.
Formula Hybrid is planning a webinar to cover project management basics which will take place before the close of
registration. Watch the Formula Hybrid announcements page http://www.formula-hybrid.org/students/announcements
for details.
On-Site Electrical Pre-Inspection
With the assistance of volunteers from the IEEE Power Electronics Society (PELS) the first electrical safety inspections
will begin three weeks before the competition at the team’s home institution.
This will give teams more time to correct rules and safety issues that might be discovered by the inspectors.
Changes in electrical rules.
The majority of changes in the electrical rules (section EV) were drafted by the electrical tech inspectors to address what
they had observed as areas of misunderstanding or confusion.
We expect that you will find the rewritten rules easier to understand and to comply with.
We look forward to seeing you at the competition!
-The Formula Hybrid rules committee
2
© 2014 SAE International
Rev. 2 - October 15, 2014
Formula Hybrid Committees
-The Formula Hybrid Rules Committee:
Mr. Daniel Bocci, Coppia Advanced Solutions, Inc.
Mr. Chris Farmer, Consultant
Mr. Douglas Fraser, P.E., Thayer School of Engineering, Dartmouth College
Mr. Tom Gee, HEV Control Systems Manager, Ford
Mr. Donald J. Gobeille Jr., P.E., Environmental Systems Products, Inc. (Ret), (Chief of Timing/Scoring)
Prof. Heath Hofmann, University of Michigan
Ms. Amy Keeler, Formula Hybrid
Ms. Kris MacCartney, IEEE (Chief Presentation Judge)
Dr. Jenna Pollock, Tesla Motors
Mr. Michael Royce, Albion Associates (Chief Mechanical Tech Inspector)
Prof. Charles R. Sullivan, Thayer School of Engineering, Dartmouth College
Prof. Douglas W. Van Citters, Thayer School of Engineering, Dartmouth College (Chief Technical Examiner)
Prof. Darris L. White, Embry-Riddle Aeronautical University
Dr. Rob Wills, P.E., Intergrid, LLC (Chief Electrical Tech Inspector and Electrical Rules Chair)
Mr. Bob Wimmer, Toyota North America (Chief Design Judge)
Ms. Kaley Zundel, SAE
-The Formula Hybrid Corporate Advisory Committee:
Mr. Tom Blackburn, Engineer, Electrified Powertrain, Ford
Mr. Jerry Bretz, Human Resource Business Partner, Powertrain Engine Engineering, Chrysler
Mr. Dennis M. Brown, Engineering Group Manager, General Motors
Ms. Nathalie Capati, Test Engineer, HEV/EV, Global Battery Systems Lab, General Motors
Ms. Alba Colon, Program Manager, NASCAR Sprint Cup Series, General Motors
Mr. Harold Flescher, Fellow, IEEE
Mr. Randy Floresca, Test Engineer, Cell and Module Test, General Motors
Mr. Doug Fraser, P.E., Technical Director, Formula Hybrid Competition, Dartmouth
Mr. Tom Gee, HEV Control Systems Manager, Ford
Mr. Wayne Haider, Electrified Powertrain Engineer, Ford
Mr. Rob Iorio, Manager, Electrified Propulsion System Implementation Engineering, Ford
Ms. Amy Keeler, Coordinating Manager, Formula Hybrid, Dartmouth
Mr. Scott Lananna, Test Engineer, Abuse and Safety Testing, General Motors
Ms. Kristen MacCartney, University Partnership Program Manager, IEEE
Mr. Zachary Mendla, Test Engineer, General Motors
Mr. Anthony Modafferi, Engineering Group Manager, Global Battery Systems, General Motors
Ms. Tara Rahmanifar, Business Manager, Electrified Powertrain Engineering, Ford
Ms. Iva Shallvari, Engine Controls & Software Engineer, Chrysler
Mr. Joe Tolkacz, Senior Manager, Chrysler
Dr. Rob Wills, P.E., Principal Engineer, Intergrid, LLC
Mr. Bob Wimmer, National Manager, Environment Research, Technical and Regulatory Affairs, Toyota
3
© 2014 SAE International
Rev. 2 - October 15, 2014
RULES CHANGES FOR 2015
For the benefit of the teams, we have provided a summary of the significant changes to the 2015 Formula
Hybrid rules. It is not a complete list and is not binding. If there are any differences between this summary and
the official rules, the Rules will prevail. Therefore, it is the responsibility of the competitors to read the
published Rules thoroughly.
Rule
Number
System
Change
Table 1
A1.3
Table 4
A9.4.3
T3.30.3
T4.5.1
T11.2.1
Figure 22
ARTICLE D3
EV1.3.1
EV3.3.3
Figure 26
EV3.3.4
EV3.3.6
EV3.3.9
EV3.4.2
EV3.4.5
EV3.6.6
EV3.6.8
EV3.6.9
EV3.6.10
EV3.7.6
EV3.8
EV4.1.5(a)
EV4.1.5(c-f)
EV4.1.6
EV4.1.7
EV4.1.8
EV4.1.9
EV4.2
EV4.4.4
EV4.4.9
Figure 29
EV4.5.8
EV4.5.10
EV4.5.12
EV4.7.1
EV4.7.2
EV4.7
EV4.7.6
EV4.7.7
EV4.8.3
Battery Capacities
Design Objectives
Required Documents
Web-based submission
Monocoque Laminate testing
Firewall rules
Critical fasteners
Critical fasteners
Running in rain
Elect Insulating Materials
Accumulator container
Accumulator segmenting
Accumulator disconnects
Accumulator indicators
Accumulator spacings
Accumulator mounting
Accumulator attachments
GLV isolation
AMS Shutdown
Team-designed AMS
AMS Test point
GLV system
Pouch Cells
GLV TSV separation
GLV TSV separation
GLV TSV separation
GLV TSV separation
GLV TSV separation
Plated prototyping boards
Positioning of tractive parts
Shrouded banana jacks
Shrouded banana jacks
Shrouded banana jack
Tractive wiring
Tractive wiring
Tractive wiring
High voltage disconnect
High voltage disconnect
HVD
HVD
HVD
Tractive activation
Changed to use more relevant (2C) rate
Updated to emphasize efficiency
Added Project Management documents
Added team responsibility for time/date accuracy
Added section
Added note.
Clarified and expanded allowable fasteners
Added illustration
Clarified damp in addition to wet
Added Note
Clarified and added HV disconnects
Added illustration
Rewritten
Removed analog voltmeter option
Added spacing requirements and table
Changed deceleration requirements
Changed specs and added monocoque requirements
Added grounding requirement for external connections
Clarified and added specific requirements
Reduced watchdog requirements
Added requirements for test port with illustrations
Added grounding requirement
Added requirements for pouch
Clarified
Added insulation requirements
Clarified
Clarified
Added documentation requirement
Added restriction
Added cross-reference
Clarified
Clarified
Added illustration
Added allowable cable
Added termination requirements
Added shield termination requirements
Clarified
Added definition of ‘ready to race’
Tools are no longer permitted for removing HVDs
Added lockout requirement and referenced OSHA document
Added recommendation for HVD location
Added note re. Ready to drive sound
4
© 2014 SAE International
Rev. 2 - October 15, 2014
EV4.9.5
EV4.9.6
EV4.10
EV4.11.2
EV4.12
EV5.1.5
EV5.1.6
EV5.1.7
EV5.1.8
Figure 31
Figure 33
EV5.5.4
EV6.1.1
EV6.1.5
EV6.1.6
ARTICLE EV7
EV7.3.1
EV8.2.12-13
S2.3
S2.5(c)
ARTICLE S3
D1.3
D1.4
ARTICLE D3
D5.5
D6.2.4
D7.18
Appendix A
Appendix B
Appendix C
Appendix H
Appendix K
Pre-charge circuit
Pre-charge and discharge
Tractive System Active Light
Ready to drive sound
TS Voltage Present
Driver system reactivation
Motors must spin free
Shutdown circuits
Shutdown circuits
Shutdown circuits
Master switch diagram
IMD operation
Fusing
Fusing
Fusing
System tests
Rain test
Charging connections
Pre-Competition inspection
Electrical scrutineering
Presentation event
Safety procedures
Vehicle integrity
Running in the rain
Acceleration scoring
Autocross procedure
Endurance scoring
Battery equivalencies
Endurance scoring
Presentation scoring sheet
IMD latching diagram
Project management
Must operate regardless of startup sequence
Added temperature considerations
Changed operating requirements
Added frequency and loudness specs
New Added additional indicator requirements
Added remote reset prohibition
Clarified
Added example state diagram
Added compliance with state diagram requirement
Added state diagram
Revised
Clarified shutdown requirements
Added note referencing tutorial
Added fuse location requirement
Added branch fuse location requirement
Added note regarding test order
Reworded rain test rule
Added charging port requirements
Added on-site electrical inspection
Removed rain test reference
ALL NEW Removed marketing – added Project Management
Added section
Clarified requirement – Electric drive must be functional
Added ‘damp’ to the classifications
Reworded for consistency
Clarified
Changed endurance scoring formula
Changed from C20 rate to 2C rate
Changed to reflect new scoring procedures
Replaced with new Project Management scoring sheet
Added ‘low-true’ version
Added Introduction to Project Management
Changes in Revision 1:
T3.21
Figure 33
EV5.3.5
Table 17
Impact Attenuator Report
Example shutdown diagram
Electrical systems shutdown
Shutdown priorities
Reworded for clarity
Changed ordering of shutdown priorities
Added note
Revised table
Changes in Revision 2:
Table 14
EV4.1.6
Conductor spacing
Conductor spacing
Added explanatory table
Removed extraneous paragraph
5
© 2014 SAE International
Rev. 2 - October 15, 2014
Index
RULES CHANGES FOR 2015 ........................................................................................................... 4
PART A - ADMINISTRATIVE REGULATIONS .................................................................................. 16
ARTICLE A1
A1.1
A1.2
A1.3
A1.4
A1.5
FORMULA HYBRID OVERVIEW AND COMPETITION .......................................................................... 16
Formula Hybrid Competition Objective ..................................................................................................16
Energy Limits ...........................................................................................................................................16
Vehicle Design Objectives .......................................................................................................................16
Good Engineering Practices ....................................................................................................................17
Judging Categories ..................................................................................................................................17
ARTICLE A2
A2.1
A2.2
A2.3
A2.4
FORMULA HYBRID VEHICLE CATEGORIES ......................................................................................... 17
Hybrid ......................................................................................................................................................17
Electric.....................................................................................................................................................18
Hybrid in Progress ...................................................................................................................................18
Electric vs. Hybrid Vehicles .....................................................................................................................18
ARTICLE A3
A3.1
A3.2
A3.3
THE FORMULA HYBRID COMPETITION ............................................................................................. 18
Open Registration ...................................................................................................................................18
Official Announcements and Competition Information..........................................................................18
Official Language .....................................................................................................................................18
ARTICLE A4
A4.1
A4.2
A4.3
A4.4
A4.5
A4.6
A4.7
A4.8
A4.9
A4.10
A4.11
FORMULA HYBRID RULES AND ORGANIZER AUTHORITY .................................................................. 18
Rules Authority .......................................................................................................................................18
Rules Validity ...........................................................................................................................................19
Rules Compliance ....................................................................................................................................19
Understanding the Rules .........................................................................................................................19
Participating in the Competition .............................................................................................................19
Violations of Intent .................................................................................................................................19
Right to Impound ....................................................................................................................................19
Restriction on Vehicle Use ......................................................................................................................19
Headings..................................................................................................................................................19
General Authority ...................................................................................................................................20
SAE Technical Standards Access ..............................................................................................................20
ARTICLE A5
A5.1
A5.2
A5.3
A5.4
A5.5
A5.6
A5.7
A5.8
INDIVIDUAL PARTICIPATION REQUIREMENTS .................................................................................. 20
Eligibility Limits .......................................................................................................................................20
Student Status .........................................................................................................................................20
Society Membership ...............................................................................................................................20
Age ..........................................................................................................................................................21
Driver’s License .......................................................................................................................................21
Driver Restrictions ...................................................................................................................................21
Liability Waiver........................................................................................................................................21
Medical Insurance ...................................................................................................................................21
ARTICLE A6
A6.1
A6.2
A6.3
A6.4
INDIVIDUAL REGISTRATION REQUIREMENTS ................................................................................... 21
SAE Student Members ............................................................................................................................21
Onsite Registration Requirement ...........................................................................................................22
Faculty Advisor ........................................................................................................................................22
Rules and Safety Officer (RSO) ................................................................................................................22
ARTICLE A7
A7.1
A7.2
VEHICLE ELIGIBILITY ......................................................................................................................... 23
Student Developed Vehicle .....................................................................................................................23
Information Sources ................................................................................................................................23
6
© 2014 SAE International
Rev. 2 - October 15, 2014
A7.3
A7.4
A7.5
A7.6
Professional Assistance ...........................................................................................................................23
Student Fabrication .................................................................................................................................23
Vehicles Used for Multiple Years ............................................................................................................23
Entries per University ..............................................................................................................................24
ARTICLE A8
A8.2
A8.3
A8.4
A8.5
A8.6
A8.7
REGISTRATION ................................................................................................................................. 24
Registration Cap ......................................................................................................................................24
Registration Dates and Times .................................................................................................................24
Registration Fees .....................................................................................................................................24
Withdrawals ............................................................................................................................................24
United States Visas..................................................................................................................................24
Vehicle shipping ......................................................................................................................................25
ARTICLE A9
A9.1
A9.2
A9.3
A9.4
VEHICLE DOCUMENTS, DEADLINES AND PENALTIES ......................................................................... 25
Required Documents ..............................................................................................................................25
Deadlines.................................................................................................................................................26
Late Submission Penalties .......................................................................................................................26
Web Based Submission ...........................................................................................................................26
ARTICLE A10
FORMS AND DOCUMENTS ............................................................................................................... 27
ARTICLE A11
A11.1
A11.2
A11.3
A11.4
A11.5
A11.6
PROTESTS ......................................................................................................................................... 27
Protests - General ...................................................................................................................................27
Preliminary Review – Required ...............................................................................................................27
Cause for Protest.....................................................................................................................................27
Protest Format and Forfeit .....................................................................................................................27
Protest Period .........................................................................................................................................27
Decision ...................................................................................................................................................28
ARTICLE A12
A12.1
A12.2
A12.3
A12.4
A12.5
A12.6
QUESTIONS ABOUT THE FORMULA HYBRID RULES .......................................................................... 28
Question Publication ...............................................................................................................................28
Question Types .......................................................................................................................................28
Frequently Asked Questions ...................................................................................................................28
Question Submission...............................................................................................................................28
Question Format .....................................................................................................................................29
Response Time ........................................................................................................................................29
PART T - GENERAL TECHNICAL REQUIREMENTS .......................................................................... 30
ARTICLE T1
T1.1
T1.2
VEHICLE REQUIREMENTS & RESTRICTIONS....................................................................................... 30
Technical Inspection................................................................................................................................30
Modifications and Repairs ......................................................................................................................30
ARTICLE T2
T2.1
T2.2
T2.3
T2.4
T2.5
GENERAL DESIGN REQUIREMENTS ................................................................................................... 31
Vehicle Configuration ..............................................................................................................................31
Bodywork ................................................................................................................................................31
Wheelbase ..............................................................................................................................................32
Vehicle Track ...........................................................................................................................................32
Visible Access ..........................................................................................................................................32
ARTICLE T3
T3.1
T3.2
T3.3
T3.4
T3.5
T3.6
T3.7
T3.8
DRIVER’S CELL .................................................................................................................................. 32
General Requirements ............................................................................................................................32
Definitions ...............................................................................................................................................32
Minimum Material Requirements ..........................................................................................................33
Alternative Tubing and Material - General .............................................................................................34
Alternative Steel Tubing ..........................................................................................................................35
Aluminum Tubing Requirements ............................................................................................................36
Composite Materials ...............................................................................................................................36
Structural Documentation – SES Submission ..........................................................................................36
7
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.9
T3.10
T3.11
T3.12
T3.13
T3.14
T3.15
T3.16
T3.17
T3.18
T3.19
T3.20
T3.21
T3.22
T3.23
T3.24
T3.25
T3.26
T3.27
T3.28
T3.29
T3.30
T3.31
T3.32
T3.33
T3.34
T3.35
T3.36
T3.37
T3.38
T3.39
T3.40
Main and Front Roll Hoops – General Requirements .............................................................................37
Main Hoop ..............................................................................................................................................40
Front Hoop ..............................................................................................................................................40
Main Hoop Bracing..................................................................................................................................41
Front Hoop Bracing .................................................................................................................................42
Other Bracing Requirements...................................................................................................................42
Other Side Tube Requirements ...............................................................................................................42
Mechanically Attached Roll Hoop Bracing ..............................................................................................42
Frontal Impact Structure .........................................................................................................................44
Bulkhead .................................................................................................................................................44
Front Bulkhead Support ..........................................................................................................................44
Impact Attenuator...................................................................................................................................44
Impact Attenuator Test Data Report Requirement ................................................................................45
Non-Crushable Objects ...........................................................................................................................46
Front Bodywork.......................................................................................................................................46
Side Impact Structure for Tube Frame Cars ............................................................................................46
Inspection Holes ......................................................................................................................................47
Composite Tubular Space Frames ...........................................................................................................47
Monocoque General Requirements ........................................................................................................47
Monocoque Inspections ..........................................................................................................................48
Monocoque Buckling Modulus – Equivalent Flat Panel Calculation .......................................................48
Monocoque Laminate Testing ................................................................................................................48
Monocoque Front Bulkhead ...................................................................................................................49
Monocoque Front Bulkhead Support......................................................................................................49
Monocoque Side Impact .........................................................................................................................49
Monocoque Main Hoop ..........................................................................................................................50
Monocoque Front Hoop..........................................................................................................................50
Monocoque Front and Main Hoop Bracing.............................................................................................50
Monocoque Impact Attenuator Attachment ..........................................................................................50
Monocoque Impact Attenuator Anti-intrusion Plate ..............................................................................50
Monocoque Attachments .......................................................................................................................50
Monocoque Driver’s Harness Attachment Points ...................................................................................51
ARTICLE T4
T4.1
T4.2
T4.3
T4.4
T4.5
T4.6
T4.7
T4.8
T4.9
COCKPIT ........................................................................................................................................... 51
Cockpit Opening ......................................................................................................................................51
Cockpit Internal Cross Section: ...............................................................................................................52
Driver’s Seat ............................................................................................................................................53
Floor Close-out ........................................................................................................................................54
Firewall ....................................................................................................................................................54
Accessibility of Controls ..........................................................................................................................56
Driver Visibility ........................................................................................................................................56
Driver Egress ...........................................................................................................................................56
Emergency Shut Down Test ....................................................................................................................57
ARTICLE T5
T5.1
T5.2
T5.3
T5.4
T5.5
T5.6
T5.7
T5.8
DRIVERS EQUIPMENT (BELTS AND COCKPIT PADDING) .................................................................... 57
Belts - General .........................................................................................................................................57
Belt, Strap and Harness Installation - General ........................................................................................58
Lap Belt Mounting ...................................................................................................................................58
Shoulder Harness ....................................................................................................................................59
Anti-Submarine Belt Mounting ...............................................................................................................60
Head Restraint ........................................................................................................................................60
Roll Bar Padding ......................................................................................................................................61
Driver’s Leg Protection ............................................................................................................................61
ARTICLE T6
T6.1
GENERAL CHASSIS RULES ................................................................................................................. 61
Suspension ..............................................................................................................................................61
8
© 2014 SAE International
Rev. 2 - October 15, 2014
T6.2
T6.3
T6.4
T6.5
T6.6
T6.7
Ground Clearance ...................................................................................................................................62
Wheels ....................................................................................................................................................62
Tires .........................................................................................................................................................62
Steering ...................................................................................................................................................62
Jacking Point............................................................................................................................................63
Rollover Stability .....................................................................................................................................63
ARTICLE T7
T7.1
T7.2
T7.3
T7.4
BRAKE SYSTEM ................................................................................................................................. 64
Brake System - General ...........................................................................................................................64
Brake Test ...............................................................................................................................................64
Brake Over-Travel Switch ........................................................................................................................64
Brake Light ..............................................................................................................................................65
ARTICLE T8
T8.1
T8.2
T8.3
T8.4
T8.5
POWERTRAIN ................................................................................................................................... 65
Coolant Fluid Limitations ........................................................................................................................65
System Sealing ........................................................................................................................................65
Transmission and Drive ...........................................................................................................................66
Drive Train Shields and Guards ...............................................................................................................66
Integrity of systems carrying fluids – Tilt Test.........................................................................................67
ARTICLE T9
T9.1
T9.2
T9.3
T9.4
T9.5
T9.6
AERODYNAMIC DEVICES .................................................................................................................. 67
Aero Dynamics and Ground Effects - General.........................................................................................67
Location ...................................................................................................................................................67
Wing Edges - Minimum Radii ..................................................................................................................67
Other Edge Radii Limitations ...................................................................................................................67
Ground Effect Devices .............................................................................................................................68
Driver Egress Requirements ....................................................................................................................68
ARTICLE T10
T10.1
T10.2
COMPRESSED GAS SYSTEMS AND HIGH PRESSURE HYDRAULICS ..................................................... 68
Compressed Gas Cylinders and Lines ......................................................................................................68
High Pressure Hydraulic Pumps and Lines ..............................................................................................68
ARTICLE T11
T11.1
T11.2
FASTENERS ....................................................................................................................................... 69
Fastener Grade Requirements ................................................................................................................69
Securing Fasteners ..................................................................................................................................69
ARTICLE T12
T12.1
T12.2
TRANSPONDERS ............................................................................................................................... 70
Transponders ..........................................................................................................................................70
Transponder Mounting – All Events ........................................................................................................70
ARTICLE T13
T13.1
T13.2
T13.3
T13.4
VEHICLE IDENTIFICATION ................................................................................................................. 71
Car Number .............................................................................................................................................71
School Name ...........................................................................................................................................72
SAE & IEEE Logos .....................................................................................................................................72
Technical Inspection Sticker Space .........................................................................................................72
ARTICLE T14
T14.1
T14.2
T14.3
T14.4
T14.5
T14.6
T14.7
T14.8
T14.9
T14.10
T14.11
T14.12
EQUIPMENT REQUIREMENTS ........................................................................................................... 72
Driver’s Equipment .................................................................................................................................72
Helmet.....................................................................................................................................................72
Balaclava .................................................................................................................................................72
Eye Protection .........................................................................................................................................72
Suit ..........................................................................................................................................................73
Underclothing .........................................................................................................................................73
Socks .......................................................................................................................................................74
Shoes .......................................................................................................................................................74
Gloves......................................................................................................................................................74
Arm Restraints ........................................................................................................................................74
Driver’s Equipment Condition .................................................................................................................74
Fire Resistant Material ............................................................................................................................74
9
© 2014 SAE International
Rev. 2 - October 15, 2014
T14.13
T14.14
Synthetic Material – Prohibited ..............................................................................................................74
Camera Mounts.......................................................................................................................................74
ARTICLE T15
T15.1
T15.2
T15.3
T15.4
T15.5
T15.6
T15.7
OTHER REQUIRED EQUIPMENT ........................................................................................................ 74
Fire Extinguishers ....................................................................................................................................74
Special Requirements..............................................................................................................................75
Chemical Spill Absorbent ........................................................................................................................75
Insulated Gloves ......................................................................................................................................75
Safety Glasses..........................................................................................................................................75
MSDS Sheets ...........................................................................................................................................75
Additional ................................................................................................................................................75
PART IC - INTERNAL COMBUSTION ENGINE POWERTRAINS ........................................................ 76
ARTICLE IC1
IC1.1
IC1.2
IC1.3
IC1.4
IC1.5
IC1.6
IC1.7
IC1.8
IC1.9
IC1.10
IC1.11
INTERNAL COMBUSTION ENGINE POWERTRAINS ............................................................................ 76
Engine Limitation ....................................................................................................................................76
Permitted modifications to a stock engine are: ......................................................................................76
Engine Inspection ....................................................................................................................................76
Starter .....................................................................................................................................................76
Air Intake System ....................................................................................................................................77
Accelerator and Accelerator Actuation ...................................................................................................78
Intake System Restrictor .........................................................................................................................79
Turbochargers & Superchargers .............................................................................................................79
Fuel Lines ................................................................................................................................................79
Fuel Injection System Requirements ......................................................................................................79
Crankcase / engine lubrication venting...................................................................................................80
ARTICLE IC2
IC2.1
IC2.2
IC2.3
IC2.4
IC2.5
IC2.6
IC2.7
IC2.8
FUEL AND FUEL SYSTEM ................................................................................................................... 80
Fuel..........................................................................................................................................................80
Fuel Additives - Prohibited ......................................................................................................................80
Fuel Temperature Changes - Prohibited .................................................................................................80
Fuel Tanks ...............................................................................................................................................80
Fuel System Location Requirements .......................................................................................................81
Fuel Tank Filler Neck & Sight Tube ..........................................................................................................81
Tank Filling Requirement ........................................................................................................................82
Venting Systems ......................................................................................................................................82
ARTICLE IC3
IC3.1
IC3.2
IC3.3
IC3.4
EXHAUST SYSTEM AND NOISE CONTROL .......................................................................................... 82
Exhaust System General ..........................................................................................................................82
Noise Measuring Procedure ....................................................................................................................83
Maximum Sound Level ............................................................................................................................83
Noise Level Re-testing .............................................................................................................................83
ARTICLE IC4
IC4.1
IC4.2
IC4.3
IC4.4
ELECTRICAL SYSTEM AND SHUTDOWN SYSTEM ............................................................................... 84
Master Switches ......................................................................................................................................84
Shutdown Buttons ..................................................................................................................................84
Batteries ..................................................................................................................................................84
Brake Over-Travel Switch ........................................................................................................................84
PART EV - ELECTRICAL POWERTRAINS AND SYSTEMS ................................................................. 85
ARTICLE EV1
EV1.1
EV1.2
EV1.3
ELECTRIC SYSTEM DEFINITIONS ........................................................................................................ 85
Basic Definitions ......................................................................................................................................85
Grounded Low Voltage and Tractive System Voltage .............................................................................85
Electrical Insulating Materials .................................................................................................................86
ARTICLE EV2
EV2.1
ELECTRIC POWERTRAIN .................................................................................................................... 86
Accelerator Pedal ....................................................................................................................................86
10
© 2014 SAE International
Rev. 2 - October 15, 2014
EV2.2
Accelerator Signal Limits Check ..............................................................................................................86
ARTICLE EV3
EV3.1
EV3.2
EV3.3
EV3.4
EV3.5
EV3.6
EV3.7
EV3.8
TRACTIVE SYSTEM - ENERGY STORAGE............................................................................................. 86
Allowed Tractive System Accumulators ..................................................................................................86
Tractive System Accumulator Container – General Requirements .........................................................87
Tractive System Accumulator Container - Electrical Configuration ........................................................87
Tractive System Accumulator Container - Mechanical Configuration ....................................................89
Accumulator Isolation Relay(s) (AIR) .......................................................................................................90
Accumulator Management System (AMS) ..............................................................................................91
Grounded Low Voltage System ...............................................................................................................93
Pouch type Lithium Ion cells ...................................................................................................................93
ARTICLE EV4
EV4.1
EV4.2
EV4.3
EV4.4
EV4.5
EV4.6
EV4.7
EV4.8
EV4.9
EV4.10
EV4.11
EV4.12
TRACTIVE SYSTEM – GENERAL REQUIREMENTS ............................................................................... 95
Separation of Tractive System and Grounded Low Voltage System .......................................................95
Positioning of tractive system parts ........................................................................................................96
Grounding ...............................................................................................................................................97
Tractive System Measuring Points (TSMP) .............................................................................................97
TSV Insulation, wiring and conduit .........................................................................................................98
Tractive System Enclosures .....................................................................................................................99
High Voltage Disconnect (HVD) .............................................................................................................100
Activating the Tractive System ..............................................................................................................100
Pre-Charge and Discharge Circuits ........................................................................................................100
Tractive-system-active Light (TSAL) ......................................................................................................101
Ready-To-Drive-Sound ..........................................................................................................................101
Tractive System Voltage Present (TSVP) indicators ..............................................................................101
ARTICLE EV5
EV5.1
EV5.2
EV5.3
EV5.4
EV5.5
SHUTDOWN CIRCUIT AND SYSTEMS............................................................................................... 102
Shutdown Circuit ...................................................................................................................................102
Master Switches ....................................................................................................................................103
Shutdown Buttons ................................................................................................................................105
Brake Over-Travel Switch ......................................................................................................................106
Insulation Monitoring Device (IMD) ......................................................................................................106
ARTICLE EV6
EV6.1
FUSING ........................................................................................................................................... 107
Fusing ....................................................................................................................................................107
ARTICLE EV7
EV7.1
EV7.2
EV7.3
ELECTRICAL SYSTEM TESTS ............................................................................................................. 108
Insulation Monitoring Device Test (IMDT) ............................................................................................108
Insulation Measurement Test (IMT) .....................................................................................................109
Rain test ................................................................................................................................................109
ARTICLE EV8
EV8.1
EV8.2
EV8.3
HIGH VOLTAGE PROCEDURES & TOOLS .......................................................................................... 109
Working on Tractive System Accumulator Containers .........................................................................109
Charging ................................................................................................................................................110
Accumulator Container Hand Cart ........................................................................................................110
ARTICLE EV9
EV9.1
EV9.2
ELECTRICAL SYSTEM FORM AND FMEA .......................................................................................... 111
Electrical System Form (ESF) .................................................................................................................111
Failure Modes and Effects Analysis (FMEA) ..........................................................................................111
ARTICLE EV10
ACRONYMS .................................................................................................................................... 112
PART S - STATIC EVENTS ........................................................................................................... 113
ARTICLE S1
STATIC EVENTS AND MAXIMUM SCORES ....................................................................................... 113
ARTICLE S2
S2.1
S2.2
S2.3
TECHNICAL INSPECTION ................................................................................................................. 113
Objective ...............................................................................................................................................113
Inspection & Testing Requirement .......................................................................................................113
Pre-Competition Electrical Inspection ..................................................................................................113
11
© 2014 SAE International
Rev. 2 - October 15, 2014
S2.4
S2.5
S2.6
S2.7
Inspection Condition .............................................................................................................................114
Inspection Process ................................................................................................................................114
Correction and Re-inspection ...............................................................................................................115
Inspection Stickers ................................................................................................................................115
ARTICLE S3
S3.1
S3.2
S3.3
S3.4
S3.5
S3.6
S3.7
S3.8
S3.9
PRESENTATION EVENT ................................................................................................................... 115
Presentation Event Objective – Project Management ..........................................................................115
Submission Requirements.....................................................................................................................115
Submission Formats ..............................................................................................................................116
Submission Deadlines ...........................................................................................................................117
Penalty for Late Submission or Non-Submission ..................................................................................117
Presentation Schedule ..........................................................................................................................117
Presentation Format .............................................................................................................................117
Data Projection Equipment ...................................................................................................................117
Scoring Formula ....................................................................................................................................117
ARTICLE S4
S4.1
S4.2
S4.3
S4.4
S4.5
S4.6
S4.7
S4.8
S4.9
S4.10
S4.11
S4.12
S4.13
S4.14
DESIGN EVENT................................................................................................................................ 118
Design Event Objective .........................................................................................................................118
Submission Requirements.....................................................................................................................118
Sustainability Requirement ...................................................................................................................119
Vehicle Drawings ...................................................................................................................................120
Submission Formats ..............................................................................................................................120
Excess Size Design Reports....................................................................................................................120
Submission Deadlines ...........................................................................................................................120
Penalty for Late Submission or Non-Submission ..................................................................................121
Penalty for Unsatisfactory Submissions ................................................................................................121
Vehicle Condition ..................................................................................................................................121
Judging Criteria .....................................................................................................................................121
Judging Sequence ..................................................................................................................................121
Scoring Formula ....................................................................................................................................122
Support Materials .................................................................................................................................122
PART D - DYNAMIC EVENTS...................................................................................................... 123
ARTICLE D1
D1.1
D1.2
D1.3
D1.4
DYNAMIC EVENTS GENERAL ........................................................................................................... 123
Maximum Scores ...................................................................................................................................123
Driving Behavior ....................................................................................................................................123
Safety Procedures .................................................................................................................................123
Vehicle Integrity and Disqualification ...................................................................................................123
ARTICLE D2
WEATHER CONDITIONS .................................................................................................................. 124
ARTICLE D3
D3.1
D3.2
D3.3
D3.4
D3.5
D3.6
D3.7
D3.8
RUNNING IN RAIN .......................................................................................................................... 124
Operating Conditions ............................................................................................................................124
Decision on Operating Conditions ........................................................................................................124
Notification ...........................................................................................................................................124
Tire Requirements .................................................................................................................................124
Event Rules ............................................................................................................................................124
Penalties ................................................................................................................................................124
Scoring...................................................................................................................................................124
Tire Changing ........................................................................................................................................125
ARTICLE D4
D4.1
DRIVER LIMITATIONS ..................................................................................................................... 126
Two Event Limit .....................................................................................................................................126
ARTICLE D5
D5.1
D5.2
ACCELERATION EVENT ................................................................................................................... 126
Acceleration Objective ..........................................................................................................................126
Acceleration Procedure .........................................................................................................................126
12
© 2014 SAE International
Rev. 2 - October 15, 2014
D5.3
D5.4
D5.5
D5.6
D5.7
D5.8
Acceleration Event ................................................................................................................................126
Tire Traction – Limitations ....................................................................................................................127
Acceleration Scoring .............................................................................................................................127
Acceleration Penalties ...........................................................................................................................127
Did Not Attempt ....................................................................................................................................127
Acceleration Scoring Formula ...............................................................................................................127
ARTICLE D6
D6.1
D6.2
D6.3
D6.4
D6.5
D6.6
D6.7
AUTOCROSS EVENT ........................................................................................................................ 128
Autocross Objective ..............................................................................................................................128
Autocross Procedure .............................................................................................................................128
Autocross Course Specifications & Speeds ...........................................................................................128
Autocross Penalties ...............................................................................................................................128
Corrected Elapsed Time ........................................................................................................................129
Best Run Scored ....................................................................................................................................129
Autocross Scoring Formula ...................................................................................................................129
ARTICLE D7
D7.1
D7.2
D7.3
D7.4
D7.5
D7.6
D7.7
D7.8
D7.9
D7.10
D7.11
D7.12
D7.13
D7.14
D7.15
D7.16
D7.17
D7.18
D7.19
D7.20
D7.21
D7.22
D7.23
ENDURANCE EVENT ....................................................................................................................... 130
Right to Change Procedure ...................................................................................................................130
Endurance Objective .............................................................................................................................130
Endurance General Procedure ..............................................................................................................130
Endurance Course Specifications & Speeds ..........................................................................................130
Energy ...................................................................................................................................................130
Hybrid Vehicles .....................................................................................................................................131
Fueling - Hybrid Vehicles .......................................................................................................................131
Charging - Electric Vehicles ...................................................................................................................131
Endurance Run Order............................................................................................................................131
Entering the Track .................................................................................................................................131
Endurance Vehicle Restarting ...............................................................................................................131
Breakdowns & Stalls..............................................................................................................................131
Endurance Driver Change Procedure ....................................................................................................132
Endurance Lap Timing ...........................................................................................................................132
Exiting the Course .................................................................................................................................133
Endurance Minimum Speed Requirement ............................................................................................133
Endurance Penalties ..............................................................................................................................133
Endurance Scoring Formula ..................................................................................................................134
Post Event Engine and Energy Check ....................................................................................................135
Endurance Event – Driving ....................................................................................................................135
Endurance Event – Passing ...................................................................................................................135
Endurance Event – Driver’s Course Walk ..............................................................................................136
Flags ......................................................................................................................................................136
ARTICLE D8
D8.1
D8.2
D8.3
D8.4
D8.5
D8.6
D8.7
RULES OF CONDUCT ....................................................................................................................... 137
Competition Objective – A Reminder ...................................................................................................137
Unsportsmanlike Conduct .....................................................................................................................137
Official Instructions ...............................................................................................................................137
Arguments with Officials .......................................................................................................................137
Alcohol and Illegal Material ..................................................................................................................137
Parties ...................................................................................................................................................138
Trash Clean-up ......................................................................................................................................138
ARTICLE D9
D9.1
D9.2
D9.3
D9.4
D9.5
D9.6
GENERAL RULES ............................................................................................................................. 138
Dynamometer Usage ............................................................................................................................138
Problem Resolution ...............................................................................................................................138
Forfeit for Non-Appearance ..................................................................................................................138
Safety Class – Attendance Required .....................................................................................................138
Drivers Meetings – Attendance Required .............................................................................................138
Personal Vehicles ..................................................................................................................................138
13
© 2014 SAE International
Rev. 2 - October 15, 2014
D9.7
Self-propelled Pit Carts, Tool Boxes, etc. - Prohibited ..........................................................................138
ARTICLE D10
D10.1
D10.2
D10.3
D10.4
D10.5
D10.6
D10.7
PIT/PADDOCK/GARAGE RULES ....................................................................................................... 139
Vehicle Movement ................................................................................................................................139
Push Bar ................................................................................................................................................139
Smoking – Prohibited ............................................................................................................................139
Fueling and Refueling ............................................................................................................................139
Energized Vehicles in the Paddock or Garage Area ..............................................................................139
Engine Running in the Paddock.............................................................................................................139
Safety Glasses........................................................................................................................................140
ARTICLE D11
D11.1
D11.2
D11.3
D11.4
DRIVING RULES .............................................................................................................................. 140
Driving Under Power .............................................................................................................................140
Driving Off-Site - Prohibited ..................................................................................................................140
Practice Track ........................................................................................................................................140
Situational Awareness ...........................................................................................................................140
ARTICLE D12
DEFINITIONS .................................................................................................................................. 140
APPENDIX A
ACCUMULATOR RATING & FUEL EQUIVALENCY ............................................................................. 142
APPENDIX B
DETERMINATION OF LAPSUM(N) VALUES ...................................................................................... 143
APPENDIX C
PRESENTATION JUDGING FORM .................................................................................................... 145
APPENDIX D
DESIGN JUDGING FORM ................................................................................................................. 147
APPENDIX E
WIRE CURRENT CAPACITY (DC) ...................................................................................................... 150
APPENDIX F
REQUIRED EQUIPMENT .................................................................................................................. 151
APPENDIX G
EXAMPLE TSV ELECTRICAL DIAGRAM ............................................................................................. 152
APPENDIX H
EXAMPLE RELAY LATCH CIRCUITS ................................................................................................... 153
APPENDIX I
SAE TECHNICAL STANDARDS INCLUDED IN THE CDS RULES ............................................................ 154
APPENDIX J
FIREWALL EQUIVALENCY TEST ....................................................................................................... 156
APPENDIX K
APPLICATION OF THE PROJECT MANAGEMENT METHOD TO FORMULA HYBRID ........................... 157
Index of Figures
FIGURE 1 - FORMULA HYBRID SUPPORT PAGE ................................................................................................................................28
FIGURE 2 - OPEN WHEEL DEFINITION ...........................................................................................................................................31
FIGURE 3 - TRIANGULATION........................................................................................................................................................33
FIGURE 4- ROLL HOOPS AND HELMET CLEARANCE ..........................................................................................................................38
FIGURE 5 - PERCY -- 95TH PERCENTILE MALE WITH HELMET ............................................................................................................39
FIGURE 6 – 95TH PERCENTILE TEMPLATE POSITIONING ...................................................................................................................39
FIGURE 7 - MAIN AND FRONT HOOP BRACING ...............................................................................................................................41
FIGURE 8 – DOUBLE-LUG JOINT ..................................................................................................................................................43
FIGURE 9 – DOUBLE LUG JOINT ...................................................................................................................................................43
FIGURE 10 – SLEEVED BUTT JOINT ...............................................................................................................................................43
FIGURE 11 – SIDE IMPACT STRUCTURE .........................................................................................................................................46
FIGURE 12 – SIDE IMPACT ZONE DEFINITION FOR A MONOCOQUE.....................................................................................................50
FIGURE 13 – ALTERNATE SINGLE BOLT ATTACHMENT ......................................................................................................................51
FIGURE 14 – COCKPIT OPENING TEMPLATE ...................................................................................................................................52
FIGURE 15 – COCKPIT INTERNAL CROSS SECTION TEMPLATE .............................................................................................................53
FIGURE 16 – EXAMPLES OF FIREWALL CONFIGURATIONS...................................................................................................................56
FIGURE 17 – LAP BELT ANGLES WITH UPRIGHT DRIVER ...................................................................................................................59
FIGURE 18 – SHOULDER HARNESS MOUNTING – TOP VIEW .............................................................................................................60
FIGURE 19 - SHOULDER HARNESS MOUNTING – SIDE VIEW .............................................................................................................60
FIGURE 20 – OVER-TRAVEL SWITCHES ..........................................................................................................................................65
14
© 2014 SAE International
Rev. 2 - October 15, 2014
FIGURE 21 - FINAL DRIVE SCATTER SHIELD EXAMPLE .......................................................................................................................66
FIGURE 22 - EXAMPLES OF POSITIVE LOCKING NUTS .........................................................................................................................70
FIGURE 23 - EXAMPLE CAR NUMBER............................................................................................................................................71
FIGURE 24- SURFACE ENVELOPE..................................................................................................................................................77
FIGURE 25 - FILLER NECK ...........................................................................................................................................................82
FIGURE 26 - EXAMPLE ACCUMULATOR SEGMENTING ......................................................................................................................88
FIGURE 27 - AMS TEST CONNECTOR ...........................................................................................................................................92
FIGURE 28 - MOLEX MINIFIT CONNECTORS ...................................................................................................................................93
FIGURE 29 - SHROUDED 4MM BANANA JACK .................................................................................................................................98
FIGURE 30 - TSVP LAMP .........................................................................................................................................................102
FIGURE 31 - EXAMPLE SHUTDOWN STATE DIAGRAM .....................................................................................................................103
FIGURE 32 - TYPICAL MASTER SWITCH .......................................................................................................................................104
FIGURE 33 – EXAMPLE MASTER SWITCH AND SHUTDOWN CIRCUIT CONFIGURATION ..........................................................................105
FIGURE 34 – INSULATION MONITORING DEVICE TEST....................................................................................................................109
FIGURE 35 - PLOT OF LAPSUM(N) CALCULATION FOR A 44-LAP ENDURANCE EVENT ............................................................................144
FIGURE 36- LATCHING CIRCUIT FOR HIGH-TRUE OUTPUT ...............................................................................................................153
FIGURE 37 - LATCHING CIRCUIT FOR LOW-TRUE OUTPUT ...............................................................................................................153
Index of Tables
TABLE 1 – 2015 ENERGY AND ACCUMULATOR LIMITS .....................................................................................................................16
TABLE 2 - EVENT POINTS............................................................................................................................................................17
TABLE 3 – REGISTRATION OPENING DATES .....................................................................................................................................24
TABLE 4 - REQUIRED DOCUMENTS ...............................................................................................................................................25
TABLE 5 – BASELINE STEEL .........................................................................................................................................................34
TABLE 6 - STEEL TUBING MINIMUM WALL THICKNESSES ..................................................................................................................35
TABLE 7 - 95TH PERCENTILE MALE TEMPLATE DIMENSIONS .............................................................................................................37
TABLE 8 – SFI / FIA STANDARDS LOGOS .......................................................................................................................................73
TABLE 9 – MAXIMUM VOLTAGES ................................................................................................................................................86
TABLE 10 - AMS SEGMENT ENERGY LIMIT ....................................................................................................................................87
TABLE 11 - ACCUMULATOR SPACING ............................................................................................................................................89
TABLE 12 - AMS VOLTAGE MONITORING .....................................................................................................................................91
TABLE 13 – AMS TEMPERATURE MONITORING .............................................................................................................................91
TABLE 14 - APPLICABILITY OF DIFFERENT SPACING RULES ..................................................................................................................95
TABLE 15 - ENCLOSURE CONDUCTOR SPACING...............................................................................................................................95
TABLE 16 - PCB CONDUCTOR SPACING ........................................................................................................................................96
TABLE 17 - SHUTDOWN PRIORITY TABLE .....................................................................................................................................106
TABLE 18 – STATIC EVENT MAXIMUM SCORES .............................................................................................................................113
TABLE 19 – MINIMUM SUSTAINABILITY DATA REQUIREMENTS........................................................................................................119
TABLE 20 – DYNAMIC EVENT MAXIMUM SCORES .........................................................................................................................123
TABLE 21 - FLAGS ...................................................................................................................................................................136
TABLE 22 – ACCUMULATOR DEVICE ENERGY CALCULATIONS ..........................................................................................................142
TABLE 23 – FUEL ENERGY EQUIVALENCIES ..................................................................................................................................142
TABLE 24 - EXAMPLE OF LAPSUM(N) CALCULATION FOR A 44-LAP ENDURANCE EVENT ........................................................................143
TABLE 25 – WIRE CURRENT CAPACITY........................................................................................................................................150
15
© 2014 SAE International
Rev. 2 - October 15, 2014
PART A - ADMINISTRATIVE REGULATIONS
ARTICLE A1
FORMULA HYBRID OVERVIEW AND COMPETITION
A1.1
Formula Hybrid Competition Objective
A1.1.1
The Formula Hybrid™ competition challenges teams of university undergraduate and graduate
students to conceive, design, fabricate, develop and compete with small, formula-style, hybridpowered and electric cars.
A1.1.2
The Formula Hybrid competition is intended as an educational program requiring students to work
across disciplinary boundaries, such as those of electrical and mechanical engineering.
A1.1.3
To give teams the maximum design flexibility and the freedom to express their creativity and
imagination there are very few restrictions on the overall vehicle design apart from the requirement
for a mechanical/electrical hybrid or electric-only drivetrain.
A1.1.4
Teams typically spend eight to twelve months designing, building, testing and preparing their
vehicles before a competition. The competitions themselves give teams the chance to demonstrate
and prove both their creativity and their engineering skills in comparison to teams from other
universities around the world.
A1.2
Energy Limits
A1.2.1
Competitiveness and high efficiency designs are encouraged through limits on Accumulator
capacities and the amount of energy that a team has available to complete the Endurance event.
A1.2.2
The accumulator capacities and endurance energy allocation will be reviewed by the Formula
Hybrid rules committee each year, and posted as early in the season as possible.
HYBRID
Endurance Energy Allocation
Maximum Accumulator Capacity1
ELECTRIC
Maximum Accumulator Capacity
35.5 MJ
4,449 Wh
5,400 Wh
Table 1 – 2015 Energy and Accumulator Limits
A1.3
Vehicle Design Objectives
For the purpose of this competition, the students are to assume that a manufacturing firm has
engaged them to design, fabricate and demonstrate a prototype hybrid-electric competition vehicle
for evaluation as a production item. The intended market is the nonprofessional weekend autocross
competitor. Therefore, the car must balance exceptional performance with fuel efficiency.
Performance will be evaluated in terms of its acceleration, braking, and handling qualities. Fuel
efficiency will be evaluated during the 44 km endurance event. The car must be low in cost, easy to
maintain, and reliable. It should accommodate drivers whose stature varies from a 5th percentile
female to a 95th percentile male. In addition, the car’s marketability is enhanced by other factors
1
Battery capacities are computed at the 2C (0.5 Hour) rate. Visit the Formula Hybrid website for information on how to convert from
other rates.
16
© 2014 SAE International
Rev. 2 - October 15, 2014
such as aesthetics, comfort and use of common parts. The manufacturing firm is planning to
produce four (4) cars per day for a limited production run. The challenge to the design team is to
develop a prototype car that best meets these goals and intents. Each design will be compared and
judged with other competing designs to determine the best overall car.
A1.4
Good Engineering Practices
A1.4.1
Vehicles entered into Formula Hybrid competitions are expected to be designed and fabricated in
accordance with good engineering practices.
A1.4.2
Note, in particular, that the electrical systems in a Formula Hybrid car present health and safety
risks unique to a hybrid/electric vehicle, and that carelessness or poor engineering can result in
serious injury or death.
A1.4.3
The organizers have produced several advisory publications that are available on the Formula
Hybrid website. It is expected that all team members will familiarize themselves with these
publications, and will apply the information in them appropriately.
A1.5
Judging Categories
The cars are judged in a series of static and dynamic events including: technical inspection,
presentation, and engineering design, solo performance trials, and high performance track
endurance. These events are scored to determine how well the car performs. In each event, the
manufacturing firm has specified minimum acceptable performance levels that are reflected in the
scoring equations.
Static Events
Presentation
Engineering Design
Dynamic Events
Acceleration - Electric
Acceleration - Unrestricted
Autocross
Endurance
Total Points
Hybrid
100
200
Electric
100
200
75
75
150
400
1000
75
150
400
925
Table 2 - Event Points
ARTICLE A2
FORMULA HYBRID VEHICLE CATEGORIES
A2.1
Hybrid
A2.1.1
A Hybrid vehicle is defined as a vehicle using a propulsion system which comprises both a 4-stroke
Internal Combustion Engine (ICE) and electrical storage (accumulator) with electric motor drive.
A2.1.2
A hybrid drive system may deploy the ICE and electric motor(s) in any configuration, including
series and/or parallel. Coupling through the road surface is permitted.
A2.1.3
To qualify as a hybrid, vehicles must be capable of:
(a)
Completing a 75 meter acceleration run in electric-only mode in less than10 Seconds or
(b)
As determined to be a hybrid by the design judges.
17
© 2014 SAE International
Rev. 2 - October 15, 2014
A2.2
Electric
An Electric vehicle is defined as a vehicle that is charged from an electrical source (or through
braking regeneration) and propelled by electric drive only.
A2.3
Hybrid in Progress
A2.3.1
A Hybrid-in-Progress (HIP) is defined as a hybrid vehicle that is still in the development stage.
A2.3.2
To be entered as an HIP, a vehicle must be clearly intended for completion as a hybrid vehicle, and
all technical document submissions, engineering drawings, etc. must include the planned hybrid
drivetrain.
A2.4
Electric vs. Hybrid Vehicles
A2.4.1
The Electric and Hybrid categories are separate. Although they compete in the same events, and
may be on the endurance course at the same time, they are scored separately and receive separate
awards.
A2.4.2
The event scoring formulas will maintain separate baselines (Tmax, Tmin) for Hybrid and Electric
categories.
Note: Electric vehicles, because they are not carrying the extra weight of engines and generating
systems, may demonstrate higher performances in some of the dynamic events. Design scores
should not be compared, as the engineering challenge between the two classes is different and
scored accordingly.
ARTICLE A3
A3.1
THE FORMULA HYBRID COMPETITION
Open Registration
The Formula Hybrid Competition has an open registration policies and will accept registrations by
student teams representing universities in any country.
A3.2
Official Announcements and Competition Information
A3.2.1
Teams are required to read the newsletters published by SAE and Formula Hybrid and to be familiar
with all official announcements concerning the competition and rules interpretations released by the
Formula Hybrid Rules Committee.
A3.2.2
Formula Hybrid posts announcements to the “News and Important Information” section of the
Formula Hybrid forum at www.formula-hybrid.org/forums. and on the announcements page of
the website http://www.formula-hybrid.org/students/announcements.
A3.3
Official Language
The official language of the Formula Hybrid competition is English.
ARTICLE A4
FORMULA HYBRID RULES AND ORGANIZER AUTHORITY
A4.1
Rules Authority
A4.1.1
The Formula Hybrid Rules are the responsibility of the Formula Hybrid Rules Committee and are
issued under the authority of the SAE Collegiate Design Series Committee. Official announcements
from the Formula Hybrid Rules Committee shall be considered part of, and shall have the same
validity as, these rules.
18
© 2014 SAE International
Rev. 2 - October 15, 2014
A4.1.2
Ambiguities or questions concerning the meaning or intent of these rules will be resolved by the
Formula Hybrid Rules Committee, SAE or by the individual competition organizers as appropriate.
(See ARTICLE A12)
A4.2
Rules Validity
The Formula Hybrid Rules posted on the Formula Hybrid website and dated for the calendar year of
the competition are the rules in effect for the competition. Rule sets dated for other years are invalid.
A4.3
Rules Compliance
A4.3.1
By entering a Formula Hybrid competition the team, members of the team as individuals, faculty
advisors and other personnel of the entering university agree to comply with, and be bound by, these
rules and all rule interpretations or procedures issued or announced by SAE, the Formula Hybrid
Rules Committee or the organizers.
A4.3.2
Any rules or regulations pertaining to the use of the competition site by teams or individuals and
which are posted, announced and/or otherwise publically available are incorporated into the these
rules by reference. As examples, all event site waiver requirements, speed limits, parking and
facility use rules apply to Formula Hybrid participants.
A4.3.3
All team members, faculty advisors and other university representatives are required to cooperate
with, and follow all instructions from, competition organizers, officials and judges.
A4.4
Understanding the Rules
Teams, team members as individuals and faculty advisors, are responsible for reading and
understanding the rules in effect for the competition in which they are participating.
A4.5
Participating in the Competition
Teams, team members as individuals, faculty advisors and other representatives of a registered
university who are present on-site at a competition are considered to be “participating in the
competition” from the time they arrive at the event site until they depart the site at the conclusion of
the competition or earlier by withdrawing.
A4.6
Violations of Intent
A4.6.1
The violation of intent of a rule will be considered a violation of the rule itself.
A4.6.2
Questions about the intent or meaning of a rule may be addressed to the Formula Hybrid Rules
Committee or by the individual competition organizers as appropriate. (See ARTICLE A12)
A4.7
Right to Impound
SAE and other competition organizing bodies reserve the right to impound any onsite registered
vehicles at any time during a competition for inspection and examination by the organizers, officials
and technical inspectors. The organizers may also impound any equipment deemed hazardous by
the technical inspectors.
A4.8
Restriction on Vehicle Use
Teams are cautioned that the vehicles designed in compliance with these Formula Hybrid Rules are
intended for competition operation only at the official Formula Hybrid competitions.
A4.9
Headings
The article, section and paragraph headings in these rules are provided only to facilitate reading:
they do not affect the paragraph contents.
19
© 2014 SAE International
Rev. 2 - October 15, 2014
A4.10
General Authority
SAE and the competition organizing bodies reserve the right to revise the schedule of any
competition and/or interpret or modify the competition rules at any time and in any manner that is,
in their sole judgment, required for the efficient operation of the event or the Formula Hybrid series
as a whole
A4.11
SAE Technical Standards Access
A4.11.1 A cooperative program of SAE’s Education Board and Technical Standards Board is making some
of SAE’s Technical Standards available to teams registered for any North American CDS
competition at no cost. The Technical Standards referenced in the Collegiate Design Series rules,
along with other standards with reference value, will be accessible online to registered teams, team
members and faculty advisors. To access the standards (1) your team must be registered for a
competition in North America and (2) the individual team member or faculty advisor wanting access
must be linked to the team in SAE’s system.
A4.11.2 Access Procedure: Once your team has registered there will be a link to the technical standards titled
“Design Standards” on the main registration screen where all the required onsite insurance
information is added. On the technical standards webpage you will have the ability to search
standards either by J-number assigned or topic of interest such as brake light.
A list of accessible SAE Technical Standards can be found in Appendix I
ARTICLE A5
A5.1
INDIVIDUAL PARTICIPATION REQUIREMENTS
Eligibility Limits
Eligibility is limited to undergraduate and graduate students to insure that this is an engineering
design competition.
A5.2
Student Status
A5.2.1
Team members must be enrolled as degree seeking undergraduate or graduate students in the
college or university of the team with which they are participating. Team members who have
graduated during the seven (7) month period prior to the competition remain eligible to participate.
A5.2.2
Teams which are formed with members from two or more Universities are treated as a single team.
A student at any University making up the team may compete at any event where the team
participates. The multiple Universities are in effect treated as one University with two campuses and
all eligibility requirements is enforced.
A5.3
Society Membership
A5.3.1
Team members must be members of at least one of the following societies:
(a) SAE
(b) IEEE
(c) SAE Australasia
(d) SAE Brazil
(e) ATA
(f) IMechE
(g) VDI
20
© 2014 SAE International
Rev. 2 - October 15, 2014
A5.3.2
Proof of membership, such as membership card, is required at the competition. Students who are
members of one of the societies listed above are not required to join any of the other societies in
order to participate in the Formula Hybrid competition.
A5.3.3
Students can join
SAE at: http://www.sae.org/students
IEEE at http://www.ieee.org/web/membership/join/join.html
Note: SAE membership is required to complete the on-line vehicle registration process, so at least
one team member must be a member of SAE.
A5.4
Age
Team members must be at least eighteen (18) years of age.
A5.5
Driver’s License
Team members who will drive a competition vehicle at any time during a competition must hold a
valid, government issued driver’s license.
A5.6
Driver Restrictions
Drivers who have driven for a professional racing team in a national or international series at any
time may not drive in any competition event. A “professional racing team” is defined as a team that
provides racing cars and enables drivers to compete in national or international racing series and
employs full time staff in order to achieve this.
A5.7
Liability Waiver
All on-site participants, including students, faculty, volunteers and guests, are required to sign a
liability waiver upon registering on-site.
A5.8
Medical Insurance
Individual medical insurance coverage is required and is the sole responsibility of the participant.
ARTICLE A6
INDIVIDUAL REGISTRATION REQUIREMENTS
A6.1
SAE Student Members
A6.1.1
If your qualifying professional society membership is with the SAE, you should link yourself to
your respective school, and complete the following information on the SAE website:
(a) Medical insurance (provider, policy/ID number, telephone number)
(b) Driver’s license (state/country, ID number)
(c) Emergency contact data (point of contact (parent/guardian, spouse), relationship, and phone
number)
A6.1.2
To do this you will need to go to “Registration” page under the specific event the team is registered
and then click on the “Register Your Team / Update Team Information” link. At this point, if you
are properly affiliated to the school/college/university, a link will appear with your team name to
select. Once you have selected the link, the registration page will appear. Selecting the “Add New
Member” button will allow individuals to include themselves with the rest of the team. This can also
be completed by team captain and faculty advisor for all team members.
A6.1.3
All students, both domestic and international, must affiliate themselves online or submit the
International Student Registration form by March 1, 2015. For additional assistance, please contact
[email protected].
21
© 2014 SAE International
Rev. 2 - October 15, 2014
A6.2
Onsite Registration Requirement
A6.2.1
Onsite registration is required of all team members and faculty advisors
A6.2.2
Registration must be completed and the credentials and/or other identification issued by the
organizers properly worn before the car can be unloaded, uncrated or worked upon in any manner.
A6.2.3
The following is required at registration:
(a) Government issued driver’s license or passport and
(b) Medical insurance card or documentation
(c) Proof of professional society membership (such as card or member number)
A6.2.4
All international student participants (or unaffiliated faculty advisors) who are not SAE members
are required to complete the International Student Registration form for the entire team found under
“Competition Resources” on the event specific webpage. Upon completion, email the form to
[email protected].
A6.2.5
All students, both domestic and international, must affiliate themselves online or submit the
International Student Registration form prior to the date shown in the Action Deadlines on the
Formula Hybrid website. For additional assistance, please contact [email protected].
NOTE: When your team is registering for a competition, only the student or faculty advisor
completing the registration needs to be linked to the school. All other students and faculty can
affiliate themselves after registration has been completed.
A6.3
Faculty Advisor
A6.3.1
Each team is expected to have a Faculty Advisor appointed by the university. The Faculty Advisor
is expected to accompany the team to the competition and will be considered by competition
officials to be the official university representative.
A6.3.2
Faculty Advisors are expected to review their team’s Structural Equivalency and Impact Attenuator
data (See Sections T3.8 andT3.21) prior to submission. Advisors are not required to certify the
accuracy of these documents.
A6.3.3
Faculty Advisors may advise their teams on general engineering and engineering project
management theory, but may not design any part of the vehicle nor directly participate in the
development of any documentation or presentation. Additionally, Faculty Advisors may neither
fabricate nor assemble any components nor assist in the preparation, maintenance, testing or
operation of the vehicle.
A6.3.4
In Brief – Faculty Advisors may not design, build or repair any part of the car.
A6.4
Rules and Safety Officer (RSO)
A6.4.1
Each team must appoint a person to be the “Rules and Safety Officer (RSO)”.
A6.4.2
The RSO must:
(a) Be present at the entire FH event.
(b) Be responsible for understanding the FH rules prior to the competition and ensuring that
competing vehicles comply with all FH rules requirements.
(c) System Documentation – Have vehicle designs, plans, schematics and supporting documents
available for review by the officials as needed.
(d) Component Documentation – Have manufacturer’s documentation and information available on
all components of the electrical system.
22
© 2014 SAE International
Rev. 2 - October 15, 2014
(e) Be responsible for team safety while at the event. This includes issues such as:
(i)
Use of safety glasses and other safety equipment
(ii) Control of shock hazards such as charging equipment and accessible high voltage sources
(iii) Control of fire hazards such as fuel, sources of ignition (grinding, welding etc.)
(iv) Safe working practices (lock-out/tag out, clean work area, use of jack stands etc.)
(f) Be the point of contact between the team and FH organizers should rules or safety issues arise.
A6.4.3
If the RSO is also a driver in a dynamic event, a backup RSO must be appointed who will take
responsibility for sections A6.4.2(e) and A6.4.2(f) (above) while the primary RSO is in the vehicle.
A6.4.4
Preferably, the RSO will be the team's faculty advisor or a member of the university's professional
staff, but the position may be held by a student member of the team.
A6.4.5
Contact information for the RSO (Name, Cell Phone number, etc.) must be provided to the
organizers at registration.
ARTICLE A7
A7.1
VEHICLE ELIGIBILITY
Student Developed Vehicle
Vehicles entered into Formula SAE competitions must be conceived, designed, fabricated and
maintained by the student team members without direct involvement from professional engineers,
automotive engineers, racers, machinists or related professionals.
A7.2
Information Sources
The student team may use any literature or knowledge related to car design and information from
professionals or from academics as long as the information is given as a discussion of alternatives
with their pros and cons.
A7.3
Professional Assistance
Professionals may not make design decisions or drawings and the Faculty Advisor may be required
to sign a statement of compliance with this restriction.
A7.4
Student Fabrication
It is the intent of the SAE Collegiate Design Series competitions to provide direct hands-on
experience to the students. Therefore, students should perform all fabrication tasks whenever
possible.
A7.5
Vehicles Used for Multiple Years
A7.5.1
Universities may enter the same vehicle for multiple years, but must document substantial
improvements and/or upgrades to the vehicle as used in the previous year’s competition.
A7.5.2
The term “substantial” will be applied at the discretion of the organizers. If a team is uncertain if
their changes qualify as substantial, they are encouraged to contact the organizers prior to the
competition.
A7.5.3
The requirements in section A7.5.1 will be waived if:
(a) A team arrives with a partially completed vehicle with the intention of entering only the static
events, or
23
© 2014 SAE International
Rev. 2 - October 15, 2014
(b) If a team is unable to enter any of the dynamic events due to not passing all the technical
inspections, or due to a non-running vehicle2. (See section S4.10 Note 2)
A7.6
Entries per University
Universities may enter up to two vehicles per competition. Note that there may be a registration wait
period imposed for a second vehicle.
ARTICLE A8
A8.1.1
REGISTRATION
Registration for the Formula Hybrid competition must be completed on-line. Online registration
must be done by either (a) an SAE member or (b) the official faculty advisor connected with the
registering university and recorded as such in the SAE record system.
Note: It typically takes at least 1 working day between the time you complete an online SAE
membership application and our system recognizes you as eligible to register your team.
A8.2
Registration Cap
The Formula Hybrid competition is capped at 35 entries. Registrations received after the entry cap is
reached will be placed on a waiting list. If no slots become available prior to the competition, the
entry fee will be refunded.
A8.3
Registration Dates and Times
A8.3.1
Registration opens on the dates shown in Table 3:
Category
Hybrid and Hybrid in Progress
Electric-only
Entry of a second team vehicle
Registration opens
Monday, October 6, 2014 10:00 AM EDT
Wednesday, October 8, 2014 10:00 AM EDT
Monday, November 3, 2014 10:00 AM EST
Table 3 – Registration opening dates
A8.3.2
Registration closes on: Monday, December 15th, 2014 at 12:59 EST.
A8.4
Registration Fees
A8.4.1
Registration fees must be paid to the organizer by the deadline specified on the Formula Hybrid
website. The registration fee for 2015 is $2,150.00 (U.S.)
A8.4.2
Registration fees are not refundable.
A8.5
Withdrawals
Registered teams that find that they will not be able to attend the Formula Hybrid competition are
requested to officially withdraw by notifying the following not later than one (1) week before the
event: [email protected]
A8.6
United States Visas
A8.6.1
Teams requiring visas to enter to the United States are advised to apply at least sixty (60) days prior
to the competition. Although most visa applications seem to go through without an unreasonable
2
It is expected that any problems causing a team to qualify for A7.5.3(b) will be rectified before reentering
the vehicle.
24
© 2014 SAE International
Rev. 2 - October 15, 2014
delay, occasionally teams have had difficulties and in several instances visas were not issued before
the competition.
A8.6.2
Don’t wait – apply early for your visa.
Note: After your team has registered for the Formula Hybrid competition, the organizers can
provide an acknowledgement your registration. We do not issue letters of invitation.
A8.6.3
Neither SAE staff nor any competition organizers are permitted to give advice on visas, customs
regulations or vehicle shipping regulations concerning the United States or any other country.
A8.7
Vehicle shipping
A8.7.1
Vehicle shipments by commercial carrier must comply with the laws and regulations of nations
from which, and to which, the car is being sent. Teams are advised to consult with their shipping
company or freight forwarder to be sure their shipment fully complies with all relevant, customs,
import /export and aviation shipping requirements. Shipments must be sent with the sending team
or university listed as the receiving party. Neither the competition organizers nor the competition
site can be listed as the receiving party.
A8.7.2
It is important to understand and comply with shippers requirements regarding the removal of
hazardous fluids from the vehicles prior to shipping either to or from the competition.
A8.7.3
Air freight shipments must comply with Federal Aviation Administration (FAA)
regulations. Teams are advised to make sure their engines, accumulators and other systems meet
FAA requirements prior to shipping.
A8.7.4
Vehicle shipping procedures are published on the Formula Hybrid website and are incorporated into
these Rules by reference.
ARTICLE A9
A9.1
VEHICLE DOCUMENTS, DEADLINES AND PENALTIES
Required Documents
The following documents supporting each vehicle must be submitted by the action deadlines posted
on the Formula Hybrid website or otherwise published by the organizers.
Section
S3.2.1
S3.2.2
T3.8
T3.21
ARTICLE A10(c)
IC2.1.3
ARTICLE A10(j)
S4.2.1
S4.2.2
S4.2.3
ARTICLE EV9
ARTICLE EV9
S2.3
Project Plan
Interim Project Report
Structural Equivalency Spreadsheet (SES)
Impact Attenuator Data (IA)
Program Submission
Fuel Request
Site Pre-Registration
Design Report
Sustainability Report
Design Spec Sheet
Failure Mode Effects Analysis (FMEA)
Electrical System Form (ESF)
Electrical Pre-Inspection
Table 4 - Required Documents
25
© 2014 SAE International
Rev. 2 - October 15, 2014
A9.2
Deadlines
A9.2.1
Volunteer judges evaluate all the required submissions and it is essential that they have enough time
to complete their work. There are no exceptions to the document submission deadlines and late
submissions will incur penalties.
A9.2.2
Because teams submit documents from different time zones, all times shown for document
submissions are GMT (Greenwich Mean Time) unless otherwise explicitly stated3.
A9.3
Late Submission Penalties
Documents received after the deadline will be penalized ten (10) points per day, or partial day late
with the following penalty caps and event exclusions:
(a) Structural Equivalency Spreadsheet (SES) – The penalty for late SES submission is capped
at negative fifty (-50) points. However, teams are advised that the SES’s are evaluated in the
order in which they are received and that late submissions will be reviewed last. Late SES
approval could delay the completion of your vehicle. We strongly recommend you submit your
SES as early as possible.
(b) Impact Attenuator Report (IA) - The penalty for late IA submissions is 10 points per day and
is capped at negative fifty (-50) points.
(c) Fuel – There is no point penalty for late submission of a fuel type order however once the
deadline has passed your team will be allocated the basic fuel type.
(d) Design Reports – The Design Report and Design Spec Sheet collectively constitute the
“Design Documents”. Late submission or failure to submit all, or any one, of the Design
Documents will be penalized at the standard ten (-10) points per day to a maximum of negative
one hundred (-100) points.
Note: The lowest possible design score is Zero (0). Negative overall design scores will not be
given.
IMPORTANT: If your Design Documents are received more than ten (10) days late, they will
not be evaluated by the judges, your team will not participate in the Design Event and will
receive zero (0) points for Design.
(e) Program Submissions – There are no penalties for late program submissions. However late
submissions will not be included in the race program, which can be an important tool for future
team fund raising.
(f)
Project Management Project Plan - Late submission or failure to submit the Project Plan will
be penalized at five (-5) points per day and is capped at negative forty (-40) points.
(g) Project Management Interim Report - Late submission or failure to submit the interim report
will be penalized at five (-5) points per day and is capped at negative ten (-10) points.
A9.4
Web Based Submission
A9.4.1
Teams must submit the required documents online through http://formula-hybrid.org/uploads
A9.4.2
The date/time of upload constitutes the official record for deadline compliance.
A9.4.3
The official time and date of document receipt will be posted on the Formula Hybrid website.
Teams are responsible for ensuring the accuracy of these postings and must notify the organizers
within three days of their submission to report a discrepancy. After three days the submission time
and date become final.
3
The change to GMT is for documents submitted to the Formula Hybrid website only. SAE website submission
deadlines, such as event entries, are as listed on that site.
26
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE A10 FORMS AND DOCUMENTS
The following forms and documents are available on the Formula Hybrid website for download:
(a) 2015 Formula Hybrid Rules (This Document)
(b) Action Deadlines
(c) Program Information Sheet (Team information for the Event Program)
(d) Mechanical Inspection Sheet
(e) Electrical Inspection Sheet
(f)
Electrical Pre-Inspection Sheet
(g) Design Specification Sheet
(h) Design Event Judging Form
(i)
Presentation Event Judging Form
(j)
Site pre-registration form (Pre-registering expedites entry into the competition site.)
Note: Formula Hybrid strives to provide student engineering teams with timely and useful
information to assist in the design and construction of their vehicles. Check the Formula Hybrid
website often for new advisory publications.
ARTICLE A11 PROTESTS
A11.1
Protests - General
It is recognized that thousands of hours of work have gone into fielding a vehicle and that teams are
entitled to all the points they can earn. We also recognize that there can be differences in the
interpretation of rules, the application of penalties and the understanding of procedures. The
officials and SAE staff will make every effort to fully review all questions and resolve problems and
discrepancies quickly and equitably
A11.2
Preliminary Review – Required
If a team has a question about scoring, judging, policies or any official action it must be brought to
the organizer’s or SAE staff’s attention for an informal preliminary review before a protest can be
filed.
A11.3
Cause for Protest
A team may protest any rule interpretation, score or official action (unless specifically excluded
from protest) which they feel has caused some actual, non-trivial, harm to their team, or has had
substantive effect on their score. Teams may not protest rule interpretations or actions that have not
caused them any substantive damage.
A11.4
Protest Format and Forfeit
All protests must be filed in writing and presented to the organizer or SAE staff by the team captain.
In order to have a protest considered, a team must post a twenty-five (25) point protest bond which
will be forfeited if their protest is rejected.
A11.5
Protest Period
Protests concerning any aspect of the competition must be filed within one-half hour (30 minutes) of
the posting of the scores of the event to which the protest relates.
27
© 2014 SAE International
Rev. 2 - October 15, 2014
A11.6
Decision
The decision of the competition protest committee regarding any protest is final.
ARTICLE A12 QUESTIONS ABOUT THE FORMULA HYBRID RULES
A12.1
Question Publication
By submitting a question to the Formula Hybrid Rules Committee or the competition’s organizing
body you and your team agree that both your question and the official answer can be reproduced
and distributed by SAE or Formula Hybrid, in both complete and edited versions, in any medium or
format anywhere in the world.
A12.2
Question Types
A12.2.1 The Committee will answer questions that are not already answered in the rules or FAQs or that
require new or novel rule interpretations. The Committee will not respond to questions that are
already answered in the rules. For example, if a rule specifies a minimum dimension for a part the
Committee will not answer questions asking if a smaller dimension can be used.
A12.3
Frequently Asked Questions
A12.3.1 Before submitting a question, check the Frequently Asked Questions section of the Formula Hybrid
website.
A12.4
Question Submission
Questions must be submitted on the Formula Hybrid Support page:
http://www.formula-hybrid.org/support
Figure 1 - Formula Hybrid Support Page
28
© 2014 SAE International
Rev. 2 - October 15, 2014
A12.5
Question Format
The following information is required:
(a) Submitter’s Name
(b) Submitter’s Email
(c) Topic (Select from the pull-down menu)
(d) University Name (put this in the box labeled “Subject”)
You may type your question into the “Message” box, or upload a document.
You will receive a confirmation email with a link to enable you to check on your question’s status.
A12.6
Response Time
Please allow a minimum of two (2) weeks for a response. The Rules Committee will respond as
quickly as possible, however responses to questions presenting new issues, or of unusual
complexity, may take more than two weeks.
Please do not resend questions.
29
© 2014 SAE International
Rev. 2 - October 15, 2014
PART T - GENERAL TECHNICAL REQUIREMENTS
ARTICLE T1
VEHICLE REQUIREMENTS & RESTRICTIONS
T1.1
Technical Inspection
T1.1.1
The following requirements and restrictions will be enforced through technical inspection.
Noncompliance must be corrected and the car re-inspected before the car is allowed to operate
under power.
T1.2
Modifications and Repairs
T1.2.1
Once the vehicle has been presented for judging in the Design Events, or submitted for Technical
Inspection, and until the vehicle is approved to compete in the dynamic events, i.e. all the inspection
stickers are awarded, the only modifications permitted to the vehicle are those directed by the
Inspector(s) and noted on the Inspection Form.
T1.2.2
Once the vehicle is approved to compete in the dynamic events, the ONLY modifications permitted
to the vehicle are:
(a) Adjustment of belts, chains and clutches
(b) Adjustment of brake bias
(c) Adjustment of the driver restraint system, head restraint, seat and pedal assembly
(d) Substitution of the head restraint or seat inserts for different drivers
(e) Adjustment to engine operating parameters, e.g. fuel mixture and ignition timing and any
software calibration changes
(f)
Adjustment of mirrors
(g) Adjustment of the suspension where no part substitution is required, (except that springs, sway
bars and shims may be changed)
(h) Adjustment of tire pressure
(i)
Adjustment of wing angle (but not the location)
(j)
Replenishment of fluids
(k) Replacement of worn tires or brake pads
(l)
The changing of wheels and tires for “wet” or “damp” conditions as allowed in D3.1 of the
Formula Hybrid Rules.
(m) Recharging of Grounded Low Voltage (GLV) supplies.
(n) Recharging of Accumulators. (See EV8.2)
T1.2.3
The vehicle must maintain all required specifications, e.g. ride height, suspension travel, braking
capacity, sound level and wing location throughout the competition.
T1.2.4
Once the vehicle is approved for competition, any damage to the vehicle that requires repair, e.g.
crash damage, electrical or mechanical damage will void the Inspection Approval. Upon the
completion of the repair and before re-entering into any dynamic competition, the vehicle MUST be
re-submitted to Technical Inspection for re-approval.
30
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE T2
GENERAL DESIGN REQUIREMENTS
T2.1
Vehicle Configuration
T2.1.1
The vehicle must be open-wheeled and open-cockpit (a formula style body) with four (4) wheels
that are not in a straight line.
T2.1.2
Definition of "Open Wheel" – Open Wheel vehicles must satisfy all of the following criteria:
(a) The top 180 degrees of the wheels/tires must be unobstructed when viewed 2.7 inches (68.6
mm) above the plane formed by the tops of the front and rear tires
(b) The wheels/tires must be unobstructed when viewed from the side.
(c) No part of the vehicle may enter a keep-out-zone defined as a circle 2.7 inches (68.6 mm) larger
radially than the outside diameter of the tire with the tires steered straight ahead with a 77kg
(170 pound) driver seated in the normal driving position. The inner sidewall of the tire (vehicle
side) is not included in this assessment. See the figure below.
Note: The dry tires will be used for all inspections. For technical inspection the keep-out-zone may
be inspected by use of a tennis ball fastened to the end of a stick. The ball will have the 2.7 inch
(68.6 mm) diameter and must be able to be freely moved around the outside of the tire without
contacting any portion of the car other than the tire.
Figure 2 - Open Wheel Definition
T2.2
Bodywork
There must be no openings through the bodywork into the driver compartment from the front of the
vehicle back to the roll bar main hoop or firewall other than that required for the cockpit opening.
Minimal openings around the front suspension components are allowed.
31
© 2014 SAE International
Rev. 2 - October 15, 2014
T2.3
Wheelbase
The car must have a wheelbase of at least 1525 mm (60 inches). The wheelbase is measured from
the center of ground contact of the front and rear tires with the wheels pointed straight ahead.
T2.4
Vehicle Track
The smaller track of the vehicle (front or rear) must be no less than 75% of the larger track.
T2.5
Visible Access
All items on the Inspection Form must be clearly visible to the technical inspectors without using
instruments such as endoscopes or mirrors. Visible access can be provided by removing body panels
or by providing removable access panels.
DRIVER’S CELL
ARTICLE T3
T3.1
General Requirements
T3.1.1
Among other requirements, the vehicle’s structure must include two roll hoops that are braced, a
front bulkhead with support system and Impact Attenuator, and side impact structures.
Note: Many teams will be retrofitting Formula SAE cars for Formula Hybrid. In most cases these
vehicles will be considerably heavier than what the original frame and suspension was designed to
carry. It is important to analyze the structure of the car and to strengthen it as required to insure that
it will handle the additional stresses.
The technical inspectors will also be paying close attention to the mounting of accumulator systems.
These can be very heavy and must be adequately fastened to the main structure of the vehicle.
T3.2
Definitions
The following definitions apply throughout the Rules document:
(a) Main Hoop - A roll bar located alongside or just behind the driver’s torso.
(b) Front Hoop - A roll bar located above the driver’s legs, in proximity to the steering wheel.
(c) Roll Hoops – Both the Front Hoop and the Main Hoop are classified as “Roll Hoops”
(d) Roll Hoop Bracing Supports – The structure from the lower end of the Roll Hoop Bracing back
to the Roll Hoop(s).
(e) Frame Member - A minimum representative single piece of uncut, continuous tubing.
(f)
Frame - The “Frame” is the fabricated structural assembly that supports all functional vehicle
systems. This assembly may be a single welded structure, multiple welded structures or a
combination of composite and welded structures.
(g) Primary Structure – The Primary Structure is comprised of the following Frame components:
(i)
Main Hoop
(ii)
Front Hoop
(iii) Roll Hoop Braces and Supports
(iv)
Side Impact Structure
(v)
Front Bulkhead
(vi)
Front Bulkhead Support System
32
© 2014 SAE International
Rev. 2 - October 15, 2014
(vii) All Frame Members, guides and supports that transfer load from the Driver’s Restraint
System into items (i) through (vi).
(h) Major Structure of the Frame – The portion of the Frame that lies within the envelope defined
by the Primary Structure. The upper portion of the Main Hoop and the Main Hoop Bracing are
not included in defining this envelope.
(i)
Front Bulkhead – A planar structure that defines the forward plane of the Major Structure of
the Frame and functions to provide protection for the driver’s feet.
(j)
Impact Attenuator – A deformable, energy absorbing device located forward of the Front
Bulkhead.
(k) Side Impact Zone – The area of the side of the car extending from the top of the floor to 350
mm (13.8 inches) above the ground and from the Front Hoop back to the Main Hoop.
(l)
Node-to-node triangulation – An arrangement of frame members projected onto a plane, where
a co-planar load applied in any direction, at any node, results in only tensile or compressive
forces in the frame members. This is also what is meant by “properly triangulated”.
Not OK
Properly Triangulated
Figure 3 - Triangulation
T3.3
Minimum Material Requirements
T3.3.1
Baseline Steel Material
The Primary Structure of the car must be constructed of:
Either: Round, mild or alloy, steel tubing (minimum 0.1% carbon) of the minimum dimensions
specified in Table 5.
Or: Approved alternatives per Rules T3.3, T3.4, T3.5 and T3.6.
33
© 2014 SAE International
Rev. 2 - October 15, 2014
ITEM or APPLICATION
OUTSIDE DIMENSION x WALL THICKNESS
Main & Front Hoops,
Shoulder Harness Mounting Bar
Round 1.0 inch (25.4 mm) x 0.095 inch (2.4 mm) or
Round 25.0 mm x 2.50 mm metric
Side Impact Structure, Front Bulkhead,
Roll Hoop Bracing,
Driver’s Restraint Harness Attachment
(except for Shoulder Harness Mounting
Bar - above)
Accumulator Protection Structure
Round 1.0 inch (25.4 mm) x 0.065 inch (1.65 mm) or
Round 25.0 mm x 1.75 mm metric or
Round 25.4 mm x 1.60 mm metric or
Square 1.00 inch x 1.00 inch x 0.049 inch or
Square 25.0 mm x 25.0 mm x 1.25 mm metric or
Square 26.0 mm x 26.0 mm x 1.2 mm metric
Main Hoop Bracing Supports,
Front Bulkhead Supports,
Protection of Tractive System Components
Round 1.0 inch (25.4 mm) x 0.049 inch (1.25 mm) or
Round 25.0 mm x 1.5 mm metric or
Round 26.0 mm x 1.2 mm metric
Table 5 – Baseline Steel
Note 1: The use of alloy steel does not allow the wall thickness to be thinner than that used for mild
steel.
Note 2: For a specific application using tubing of the specified outside diameter but with greater
wall thickness, or of the specified wall thickness and a greater outside diameter, or replacing round
tubing with square tubing of the same or larger size to those listed above, are NOT rules deviation
requiring approval.
Note 3: Except for inspection holes, any holes drilled in any regulated tubing require the submission
of an SES.
Note 4: Baseline steel properties used for calculations to be submitted in an SES may not be lower
than the following:
Bending and buckling strength calculations:
Young’s Modulus (E) =
200 GPa (29,000 ksi)
Yield Strength (Sy) =
305 MPa (44.2 ksi)
Ultimate Strength (Su) =
365 MPa (52.9 ksi)
Welded monocoque attachment points or welded tube joint calculations:
Yield Strength (Sy) =
180 MPa (26 ksi)
Ultimate Strength (Su) =
300 MPa (43.5 ksi)
T3.3.2
Where welded tubing reinforcements are required (e.g. inserts for bolt holes or material to support
suspension cutouts) the tubing must retain the baseline cold rolled strength while using the welded
strength for the additional reinforcement material.
T3.4
Alternative Tubing and Material - General
T3.4.1
Alternative tubing geometry and/or materials may be used except that the Main Roll Hoop and Main
Roll Hoop Bracing must be made from steel, i.e. the use of aluminum or titanium tubing or
composites for these components is prohibited.
34
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.4.2
Titanium or magnesium on which welding has been utilized may not be used for any part of the
Primary Structure. This includes the attachment of brackets to the tubing or the attachment of the
tubing to other components.
T3.4.3
If a team chooses to use alternative tubing and/or materials they must submit a “Structural
Equivalency Spreadsheet” per Rule T3.8. The teams must submit calculations for the material they
have chosen, demonstrating equivalence to the minimum requirements found in Section T3.3.1 for
yield and ultimate strengths in bending, buckling and tension, for buckling modulus and for energy
dissipation.
Note: The Buckling Modulus is defined as EI, where, E = modulus of Elasticity, and I = area
moment of inertia about the weakest axis.
T3.4.4
To be considered as a structural tube in the SES Submission (T3.8) tubing cannot have an outside
dimension less than 25 mm (1.0 inches) or a wall thickness less than that listed in T3.5 or T3.6.
T3.4.5
If a bent tube is used anywhere in the primary structure, other than the front and main roll hoops, an
additional tube must be attached to support it. The attachment point must be the position along the
tube where it deviates farthest from a straight line connecting both ends. The support tube must
have the same diameter and thickness as the bent tube. The support tube must terminate at a node of
the chassis.
T3.4.6
Any chassis design that is a hybrid of the baseline and monocoque rules, must meet all relevant
rules requirements, e.g. a sandwich panel side impact structure in a tube frame chassis must meet
the requirements of rules T3.27, T3.28, T3.29, T3.30 and T3.33.
Note: It is allowable for the properties of tubes and laminates to be combined to prove equivalence.
E.g. in a side-impact structure consisting of one tube as per T3.3 and a laminate panel, the panel
only needs to be equivalent to two side-impact tubes.
T3.5
Alternative Steel Tubing
Minimum Wall Thickness Allowed:
MATERIAL & APPLICATION
MINIMUM WALL THICKNESS
Front and Main Roll Hoops
Shoulder Harness Mounting Bar
2.0 mm (0.079 inch)
Roll Hoop Bracing
Roll Hoop Bracing Supports
Side Impact Structure
Front Bulkhead
Front Bulkhead Support
Driver’s Harness Attachment (Except for
Shoulder Harness Mounting Bar - above)
Protection of accumulators
Protection of TSV components
1.2 mm (0.047 inch)
Table 6 - Steel Tubing Minimum Wall Thicknesses
35
© 2014 SAE International
Rev. 2 - October 15, 2014
Note 1: All steel is treated equally - there is no allowance for alloy steel tubing, e.g. SAE 4130, to
have a thinner wall thickness than that used with mild steel.
Note 2: To maintain EI with a thinner wall thickness than specified in T3.3.1, the outside diameter
MUST be increased.
Note 3: To maintain the equivalent yield and ultimate tensile strength the same cross-sectional area
of steel as the baseline tubing specified in T3.3.1 must be maintained.
T3.6
Aluminum Tubing Requirements
T3.6.1
Minimum Wall Thickness: Aluminum Tubing 3.0 mm (0.118 inch)
T3.6.2
The equivalent yield strength must be considered in the “as-welded” condition, (Reference:
WELDING ALUMINUM (latest Edition) by the Aluminum Association, or THE WELDING
HANDBOOK, Volume 4, 7th Ed., by The American Welding Society), unless the team demonstrates
and shows proof that the frame has been properly solution heat treated and artificially aged.
T3.6.3
Should aluminum tubing be solution heat-treated and age hardened to increase its strength after
welding; the team must supply sufficient documentation as to how the process was performed. This
includes, but is not limited to, the heat-treating facility used, the process applied, and the fixturing
used.
T3.7
Composite Materials
T3.7.1
If any composite or other material is used, the team must present documentation of material type,
e.g. purchase receipt, shipping document or letter of donation, and of the material properties. Details
of the composite lay-up technique as well as the structural material used (cloth type, weight, and
resin type, number of layers, core material, and skin material if metal) must also be submitted. The
team must submit calculations demonstrating equivalence of their composite structure to one of
similar geometry made to the minimum requirements found in Section T3.3.1. Equivalency
calculations must be submitted for energy dissipation, yield and ultimate strengths in bending,
buckling, and tension. Submit the completed “Structural Equivalency Spreadsheet” per Section T3.8
T3.7.2
Composite materials are not allowed for the Main Hoop or the Front Hoop.
T3.8
Structural Documentation – SES Submission
All equivalency calculations must prove equivalency relative to steel grade SAE/AISI 1010.
T3.8.1
All teams must submit a Structural Equivalency Spreadsheet (SES) even if they are not planning to
use alternative materials or tubing sizes to those specified in T3.3.1 Baseline Steel Materials.
T3.8.2
The use of alternative materials or tubing sizes to those specified in T3.3.1 “Baseline Steel
Material,” is allowed, provided they have been judged by a technical review to have equal or
superior properties to those specified in T3.3.1.
T3.8.3
Approval of alternative material or tubing sizes will be based upon the engineering judgment and
experience of the chief technical inspector or his appointee.
T3.8.4
The technical review is initiated by completing the “Structural Equivalency Spreadsheet” (SES)
which can be downloaded from the Formula Hybrid website.
T3.8.5
Structural Equivalency Spreadsheet – Submission
SESs must be submitted via the Formula Hybrid Document Upload page. See Section A9.4
Do Not Resubmit SES’s unless instructed to do so.
T3.8.6
Vehicles completed under an approved SES must be fabricated in accordance with the materials and
processes described in the SES.
36
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.8.7
Teams must bring a copy of the approved SES with them to Technical Inspection.
Comment - The resubmission of an SES that was written and submitted for a competition in a
previous year is strongly discouraged. Each team is expected to perform their own tests and to
submit SESs based on their original work. Understanding the engineering that justifies the
equivalency is essential to discussing your work with the officials.
T3.9
Main and Front Roll Hoops – General Requirements
T3.9.1
The driver’s head and hands must not contact the ground in any rollover attitude.
T3.9.2
The Frame must include both a Main Hoop and a Front Hoop as shown in Figure 4.
T3.9.3
When seated normally and restrained by the Driver’s Restraint System, the helmet of a 95th
percentile male (anthropometrical data; See Table 7) and all of the team’s drivers must:
(a) Be a minimum of 50.8 mm (2 inches) from the straight line drawn from the top of the main
hoop to the top of the front hoop. (Figure 4a)
(b) Be a minimum of 50.8 mm (2 inches) from the straight line drawn from the top of the main
hoop to the lower end of the main hoop bracing if the bracing extends rearwards. (Figure 4b)
(c) Be no further rearwards than the rear surface of the main hoop if the main hoop bracing
extends forwards. (Figure 4c)
A two dimensional template used to represent the 95th percentile male is made to the
following dimensions:
 A circle of diameter 200 mm (7.87 inch) will represent the hips and buttocks.
 A circle of diameter 200 mm (7.87 inch) will represent the shoulder/cervical
region.
 A circle of diameter 300 mm (11.81 inch) will represent the head (with
helmet).
 A straight line measuring 490 mm (19.29 inch) will connect the centers of the
two 200 mm circles.
 A straight line measuring 280 mm (11.02 inch) will connect the centers of the
upper 200 mm circle and the 300 mm head circle.
Table 7 - 95th Percentile Male Template Dimensions
37
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 4- Roll Hoops and Helmet Clearance
38
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 5 - Percy -- 95th Percentile Male with Helmet
Figure 6 – 95th Percentile Template Positioning
39
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.9.4
The 95th percentile male template will be positioned as follows: (See Figure 6)
(a) The seat will be adjusted to the rearmost position,
(b) The pedals will be placed in the most forward position.
(c) The bottom 200 mm circle will be placed on the seat bottom such that the distance between the
center of this circle and the rearmost face of the pedals is no less than 915 mm (36 inches).
(d) The middle 200 mm circle, representing the shoulders, will be positioned on the seat back.
(e) The upper 300 mm circle will be positioned no more than 25.4 mm (1 inch) away from the
head restraint (i.e. where the driver’s helmet would normally be located while driving).
IMPORTANT: If the requirements of T3.9.3 are not met with the 95th percentile male template, the
car will not receive a Technical Inspection Sticker and will not be allowed to compete in the
dynamic events.
T3.9.5
Drivers who do not meet the helmet clearance requirements of T3.9.3 will not be allowed to drive in
the competition.
T3.9.6
The minimum radius of any bend, measured at the tube centerline, must be at least three times the
tube outside diameter. Bends must be smooth and continuous with no evidence of crimping or wall
failure.
T3.9.7
The Main Hoop and Front Hoop must be securely integrated into the Primary Structure using
gussets and/or tube triangulation.
T3.10
Main Hoop
T3.10.1 The Main Hoop must be constructed of a single piece of uncut, continuous, closed section steel
tubing per Rule T3.3.1
T3.10.2 The use of aluminum alloys, titanium alloys or composite materials for the Main Hoop is prohibited.
T3.10.3 The Main Hoop must extend from the lowest Frame Member on one side of the Frame, up, over and
down the lowest Frame Member on the other side of the Frame.
T3.10.4 In the side view of the vehicle, the portion of the Main Roll Hoop that lies above its attachment
point to the Major Structure of the Frame must be within ten degrees (10°) of the vertical.
T3.10.5 In the side view of the vehicle, any bends in the Main Roll Hoop above its attachment point to the
Major Structure of the Frame must be braced to a node of the Main Hoop Bracing Support structure
with tubing meeting the requirements of Roll Hoop Bracing as per Rule T3.3.1
T3.10.6 In the front view of the vehicle, the vertical members of the Main Hoop must be at least 380 mm (15
inch) apart (inside dimension) at the location where the Main Hoop is attached to the Major
Structure of the Frame.
T3.11
Front Hoop
T3.11.1 The Front Hoop must be constructed of closed section metal tubing per Rule T3.3.1.
T3.11.2 The Front Hoop must extend from the lowest Frame Member on one side of the Frame, up, over and
down to the lowest Frame Member on the other side of the Frame.
T3.11.3 With proper gusseting and/or triangulation, it is permissible to fabricate the Front Hoop from more
than one piece of tubing.
T3.11.4 The top-most surface of the Front Hoop must be no lower than the top of the steering wheel in any
angular position.
40
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.11.5 The Front Hoop must be no more than 250 mms (9.8 inches) forward of the steering wheel. This
distance shall be measured horizontally, on the vehicle centerline, from the rear surface of the Front
Hoop to the forward most surface of the steering wheel rim with the steering in the straight-ahead
position.
T3.11.6 In side view, no part of the Front Hoop can be inclined at more than twenty degrees (20°) from the
vertical.
T3.12
Main Hoop Bracing
T3.12.1 Main Hoop braces must be constructed of closed section steel tubing per Rule T3.3.1.
T3.12.2 The Main Hoop must be supported by two braces extending in the forward or rearward direction on
both the left and right sides of the Main Hoop.
T3.12.3 In the side view of the Frame, the Main Hoop and the Main Hoop braces must not lie on the same
side of the vertical line through the top of the Main Hoop, i.e. if the Main Hoop leans forward, the
braces must be forward of the Main Hoop, and if the Main Hoop leans rearward, the braces must be
rearward of the Main Hoop.
T3.12.4 The Main Hoop braces must be attached as near as possible to the top of the Main Hoop but not
more than 160 mm (6.3inch) below the top-most surface of the Main Hoop. The included angle
formed by the Main Hoop and the Main Hoop braces must be at least thirty degrees (30°). See:
Figure 7
Figure 7 - Main and Front Hoop Bracing
T3.12.5 The Main Hoop braces must be straight, i.e. without any bends.
T3.12.6 The attachment of the Main Hoop braces must be capable of transmitting all loads from the Main
Hoop into the Major Structure of the Frame without failing. From the lower end of the braces there
must be a properly triangulated structure back to the lowest part of the Main Hoop and the node at
which the upper side impact tube meets the Main Hoop. This structure must meet the minimum
requirements for Main Hoop Bracing Supports (see Rule T3.3) or an SES approved alternative.
Bracing loads must not be fed solely into the engine, transmission or differential, or through
suspension components.
41
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.12.7 If any item which is outside the envelope of the Primary Structure is attached to the Main Hoop
braces, then additional bracing must be added to prevent bending loads in the braces in any rollover
attitude.
T3.13
Front Hoop Bracing
T3.13.1 Front Hoop braces must be constructed of material per Rule T3.3.1.
T3.13.2 The Front Hoop must be supported by two braces extending in the forward direction on both the left
and right sides of the Front Hoop.
T3.13.3 The Front Hoop braces must be constructed such that they protect the driver’s legs and should
extend to the structure in front of the driver’s feet.
T3.13.4 The Front Hoop braces must be attached as near as possible to the top of the Front Hoop but not
more than 50.8 mm (2 in) below the top-most surface of the Front Hoop. See: Figure 7
T3.13.5 If the Front Hoop leans rearwards by more than ten degrees (10°) from the vertical, it must be
supported by additional bracing to the rear. This bracing must be constructed of material per Rule
T3.3.1.
T3.14
Other Bracing Requirements
Where the braces are not welded to steel Frame Members, the braces must be securely attached to
the Frame using 8 mm Metric Grade 8.8 (5/16 in SAE Grade 5), or stronger, bolts. Mounting plates
welded to the Roll Hoop braces must be at least 2.0 mm (0.080inch) thick steel.
T3.15
Other Side Tube Requirements
If there is a Roll Hoop brace or other frame tube alongside the driver, at the height of the neck of
any of the team’s drivers, a metal tube or piece of sheet metal must be firmly attached to the Frame
to prevent the drivers’ shoulders from passing under the roll hoop brace or frame tube, and his/her
neck contacting this brace or tube.
T3.16
Mechanically Attached Roll Hoop Bracing
T3.16.1 Roll Hoop bracing may be mechanically attached.
T3.16.2 Any non-permanent joint at either end must be either a double-lug joint as shown in Figure 8 and
Figure 9 or a sleeved butt joint as shown in Figure 10.
42
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 8 – Double-Lug Joint
Figure 9 – Double Lug Joint
Figure 10 – Sleeved Butt Joint
T3.16.3 The threaded fasteners used to secure non-permanent joints are considered critical fasteners and
must comply with ARTICLE T11.
T3.16.4 No spherical rod ends are allowed.
T3.16.5 For double-lug joints, each lug must be at least 4.5 mm (0.177inch) thick steel, measure 25 mm
(1.0inch) minimum perpendicular to the axis of the bracing and be as short as practical along the
axis of the bracing.
T3.16.6 All double-lug joints, whether fitted at the top or bottom of the tube, must include a capping
arrangement. (See Figure 8 and Figure 9)
T3.16.7 In a double-lug joint the pin or bolt must be 10 mm Metric Grade 9.8 (3/8 in. SAE Grade 8)
minimum. The attachment holes in the lugs and in the attached bracing must be a close fit with the
pin or bolt.
T3.16.8 For sleeved butt joints (Figure 10), the sleeve must have a minimum length of 76 mm (3 inch); 38
mm (1.5 inch) on either side of the joint, and be a close-fit around the base tubes. The wall thickness
43
© 2014 SAE International
Rev. 2 - October 15, 2014
of the sleeve must be at least that of the base tubes. The bolts must be 6 mm Metric Grade 9.8 (1/4
inch SAE Grade 8) minimum. The holes in the sleeves and tubes must be a close-fit with the bolts.
T3.17
Frontal Impact Structure
T3.17.1 The driver’s feet and legs must be completely contained within the Major Structure of the Frame.
While the driver’s feet are touching the pedals, in side and front views no part of the driver’s feet or
legs can extend above or outside of the Major Structure of the Frame.
T3.17.2 Forward of the Front Bulkhead must be an energy-absorbing Impact Attenuator.
T3.18
Bulkhead
T3.18.1 The Front Bulkhead must be constructed of closed section tubing per Rule T3.3.1.
T3.18.2 Except as allowed byT3.22.2, The Front Bulkhead must be located forward of all non-crushable
objects, e.g. batteries, master cylinders, hydraulic reservoirs.
T3.18.3 The Front Bulkhead must be located such that the soles of the driver’s feet, when touching but not
applying the pedals, are rearward of the bulkhead plane. (This plane is defined by the forward-most
surface of the tubing.) Adjustable pedals must be in the forward most position.
T3.19
Front Bulkhead Support
T3.19.1 The Front Bulkhead must be securely integrated into the Frame.
T3.19.2 The Front Bulkhead must be supported back to the Front Roll Hoop by a minimum of three (3)
Frame Members on each side of the vehicle with one at the top (within 50.8 mm (2 inches) of its
top-most surface), one (1) at the bottom, and one (1) as a diagonal brace to provide triangulation.
T3.19.3 The triangulation must be node-to-node, with triangles being formed by the Front Bulkhead, the
diagonal and one of the other two required Front Bulkhead Support Frame Members.
T3.19.4 All the Frame Members of the Front Bulkhead Support system listed above must be constructed of
closed section tubing per Section T3.3.1.
T3.20
Impact Attenuator
T3.20.1 The Impact Attenuator must be:
(a) Installed forward of the Front Bulkhead.
(b) At least 200 mm (7.8inch) long, with its length oriented along the fore/aft axis of the Frame.
(c) At least 100 mm (3.9inch) high and 200 mm (7.8inch) wide for a minimum distance of 200
mm (7.8inch) forward of the Front Bulkhead. Such that it cannot penetrate the Front Bulkhead
in the event of an impact.
(d) Attached securely and directly to the Front Bulkhead and not by being part of non-structural
bodywork.
T3.20.2 The attachment of the Impact Attenuator must be constructed to provide an adequate load path for
transverse and vertical loads in the event of off-center and off-axis impacts.
T3.20.3 The attachment of the Impact Attenuator to the anti-intrusion plate requires an approved “Structural
Equivalency Spreadsheet” per Article T3.8 that shows equivalency to a minimum of four (4) 8 mm
Grade 8.8 (5/16 inch Grade 5) bolts.
T3.20.4 On all cars, a 1.5 mm (0.060inch) solid steel or 4.0 mm (0.157inch) solid aluminum “anti-intrusion
plate” must be integrated into the Impact Attenuator. If the IA plate is bolted to the Front Bulkhead,
it must be the same size as the outside dimensions of the Front Bulkhead. If it is welded to the Front
Bulkhead, it must extend at least to the centerline of the Front Bulkhead tubing.
44
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.20.5 If the anti-intrusion plate is not integral with the frame, i.e. welded, a minimum of four (4) 8 mm
Metric Grade 8.8 (5/16 inch SAE Grade 5) bolts must attach the Impact Attenuator to the Front
Bulkhead.
T3.20.6 Alternative designs of the anti-intrusion plate required by T3.20.4 that do not comply with the
minimum specifications given above require an approved “Structural Equivalency Spreadsheet” per
Article T3.9. Equivalency must also be proven for perimeter shear strength of the proposed design.
T3.21
Impact Attenuator Test Data Report Requirement
T3.21.1 All teams must submit calculations and/or test data to show that their Impact Attenuator, when
mounted on the front of their vehicle and run into a solid, non-yielding impact barrier with a
velocity of impact of 7.0 meters/second (23.0 ft/sec), would give an average deceleration of the
vehicle not to exceed 20 g, with a peak deceleration less than or equal to 40 g's.
T3.21.2 Calculations must be based on the actual vehicle mass with a 175 lb. driver, full fluids, and rounded
up to the nearest 100 lb.
Note: Teams may only use the “Standard” FSAE impact attenuator design and data
submission process if their vehicle mass with driver is 300 kgs (661 lbs) or less.
To be eligible to utilize the “Standard” FSAE impact attenuator, teams must either have
previously brought a Formula Hybrid vehicle that weighs under 300 kgs (661 lbs) with driver
to a Formula Hybrid competition, or submit a detailed mass measurement spreadsheet
covering all the vehicle’s components as part of the Impact Attenuator Data Report, showing
that the new vehicle meets the above requirements.
T3.21.3 When using acceleration data, the average deceleration must be calculated based on the raw data.
The peak deceleration can be assessed based on the raw data, and if peaks above the 40g limit are
apparent in the data, it can then be filtered with a Channel Filter Class (CFC) 60 (100 Hz) filter per
SAE Recommended Practice J211 “Instrumentation for Impact Tests”, or a 100 Hz, 3rd order,
lowpass Butterworth (-3dB at 100 Hz) filter.
T3.21.4 A schematic of the test method must be supplied along with photos of the attenuator before and after
testing.
T3.21.5 The test piece must be presented at technical inspection for comparison to the photographs and the
attenuator fitted to the vehicle.
T3.21.6 The report must be submitted electronically in Adobe Acrobat ® format (*.pdf file) to the address
and by the date provided in the Action Deadlines provided on the Formula Hybrid website. This
material must be a single file (text, drawings, data or whatever you are including).
T3.21.7 The Impact Attenuator Data Report must be named as follows:
carnumber_schoolname_competitioncode_IAD.pdf using the assigned car number, the complete
school name and competition code e.g.
087_University of SAE_FH_IAD.pdf
T3.21.8 Teams that submit their Impact Attenuator Data Report after the due date will be penalized as listed
in section A9.2.
T3.21.9 Impact Attenuator Reports will be evaluated by the organizers and the evaluations will be passed to
the Design Event Captain for consideration in that event.
T3.21.10 During the test, the attenuator must be attached to the anti-intrusion plate using the intended vehicle
attachment method. The anti-intrusion plate must be spaced at least 50 mm (2 inches) from any rigid
surface. No part of the anti-intrusion plate may permanently deflect more than 25.1 mm (1 inch)
beyond the position of the anti-intrusion plate before the test.
45
© 2014 SAE International
Rev. 2 - October 15, 2014
Note: The 25.4 mm (1 inch) spacing represents the front bulkhead support and insures that the plate
does not intrude excessively into the cockpit.
T3.21.11 Dynamic testing (sled, pendulum, drop tower, etc.) of the impact attenuator may only be done at a
dedicated test facility. The test facility may be part of the University but must be supervised by
professional staff or University faculty. Teams are not allowed to construct their own dynamic test
apparatus. Quasi-static testing may be performed by teams using their universities
facilities/equipment, but teams are advised to exercise due care when performing all tests.
T3.22
Non-Crushable Objects
T3.22.1 Except as allowed by T3.22.2, all non-crushable objects (e.g. batteries, master cylinders, hydraulic
reservoirs) must be rearward of the bulkhead. No non-crushable objects are allowed in the impact
attenuator zone.
T3.22.2 The front wing and wing supports may be forward of the Front Bulkhead, but may NOT be located
in or pass through the Impact Attenuator. If the wing supports are in front of the Front Bulkhead, the
supports must be included in the test of the Impact Attenuator for T3.21.
T3.23
Front Bodywork
T3.23.1 Sharp edges on the forward facing bodywork or other protruding components are prohibited.
T3.23.2 All forward facing edges on the bodywork that could impact people, e.g. the nose, must have
forward facing radii of at least 38 mm (1.5 inches). This minimum radius must extend to at least
forty-five degrees (45°) relative to the forward direction, along the top, sides and bottom of all
affected edges.
T3.24
Side Impact Structure for Tube Frame Cars
The Side Impact Structure must meet the requirements listed below.
T3.24.1 The Side Impact Structure for tube frame cars must be comprised of at least three (3) tubular
members located on each side of the driver while seated in the normal driving position, as shown in
Figure 11
Figure 11 – Side Impact Structure
46
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.24.2 The three (3) required tubular members must be constructed of material per Section T3.3.
T3.24.3 The locations for the three (3) required tubular members are as follows:
(a) The upper Side Impact Structural member must connect the Main Hoop and the Front Hoop.
With a 77kg (170 pound) driver seated in the normal driving position all of the member must
be at a height between 300 mm (11.8 inches) and 350 mm (13.8 inches) above the ground. The
upper frame rail may be used as this member if it meets the height, diameter and thickness
requirements.
(b) The lower Side Impact Structural member must connect the bottom of the Main Hoop and the
bottom of the Front Hoop. The lower frame rail/frame member may be this member if it meets
the diameter and wall thickness requirements.
(c) The diagonal Side Impact Structural member must connect the upper and lower Side Impact
Structural members forward of the Main Hoop and rearward of the Front Hoop.
T3.24.4 With proper gusseting and/or triangulation, it is permissible to fabricate the Side Impact Structural
members from more than one piece of tubing.
T3.24.5 Alternative geometry that does not comply with the minimum requirements given above requires an
approved “Structural Equivalency Spreadsheet” per Rule T3.8.
T3.25
Inspection Holes
T3.25.1 To allow the verification of tubing wall thicknesses, 4.5 mm (0.18 inch) inspection holes must be
drilled in a non-critical location of both the Main Hoop and the Front Hoop.
T3.25.2 In addition, the Technical Inspectors may check the compliance of other tubes that have minimum
dimensions specified in T3.3.1. This may be done by the use of ultra-sonic testing or by the drilling
of additional inspection holes at the inspector’s request.
T3.25.3 Inspection holes must be located so that the outside diameter can be measured across the inspection
hole with a vernier caliper, i.e. there must be access for the vernier caliper to the inspection hole and
to the outside of the tube one hundred eighty degrees (180°) from the inspection hole.
T3.26
Composite Tubular Space Frames
Composite tubular space frames are not allowed for Formula Hybrid.
T3.27
Monocoque General Requirements
T3.27.1 All equivalency calculations must prove equivalency relative to steel grade SAE/AISI 1010.
T3.27.2 All sections of the rules apply to monocoque structures except for the following sections which
supplement or supersede other rule sections.
T3.27.3 Monocoque construction requires an approved Structural Equivalency Spreadsheet, per Section
T3.8. The form must demonstrate that the design is equivalent to a welded frame in terms of energy
dissipation, yield and ultimate strengths in bending, buckling and tension. Information must include:
material type(s), cloth weights, resin type, fiber orientation, number of layers, core material, and
lay-up technique. The 3 point bend test and shear test data and pictures must also be included as per
T3.30 Monocoque Laminate Testing. The Structural Equivalency must address each of the items
below. Data from the laminate testing results must be used as the basis for any strength or stiffness
calculations.
T3.27.4 Composite and metallic monocoques have the same requirements.
T3.27.5 Composite monocoques must meet the materials requirements in Rule T3.7 Composite Materials.
47
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.28
Monocoque Inspections
T3.28.1 Due to the monocoque rules and methods of manufacture it is not always possible to inspect all
aspects of a monocoque during technical inspection. For items which cannot be verified by an
inspector it is the responsibility of the team to provide documentation, both visual and/or written,
that the requirements have been met. Generally the following items should be possible to be
confirmed by the technical inspector:
(a) Verification of the Main Hoop outer diameter and wall thickness where it protrudes above the
monocoque
(b) Visual verification that the Main Hoop goes to the lowest part of the tub, locally
(c) Verify mechanical attachment of Main Hoop to tub exists and matches the SES, at all points
shown on the SES.
(d) Verify the outside diameter and wall thickness of the Front Hoop by providing access as
required by Rule T3.25.3.
(e) Verify visually or by feel that the Front Hoop is installed.
(f)
Verify that the Front Hoop goes to the lowest part of the tub, locally.
(g) Verify mechanical attachment of the Front Hoop (if included) against the SES.
T3.29
Monocoque Buckling Modulus – Equivalent Flat Panel Calculation
When specified in the rules, the EI of the monocoque must be calculated as the EI of a flat panel
with the same composition as the monocoque about the neutral axis of the laminate. The curvature
of the panel and geometric cross section of the monocoque must be ignored for these calculations.
Note: Calculations of EI that do not reference T3.29 may take into account the actual geometry of
the monocoque.
T3.30
Monocoque Laminate Testing
T3.30.1 Teams must build a representative flat panel section of the monocoque side impact zone (“zone” is
defined in T3.32.2 and T3.2(k)) and perform a 3 point bending test on this panel. They must prove
by physical test that a section 200mm (7.9 inches) x 500 mm (19.7 inches) has at least the same
properties as a baseline steel side impact tube (See T3.3.1 “Baseline Steel Materials”) for bending
stiffness and two side impact tubes for yield and ultimate strength.
The data from these tests and pictures of the test samples must be included in the SES, the test
results will be used to derive strength and stiffness properties used in the SES formulae for all
laminate panels. The test specimen must be presented at technical inspection. If the test specimen
does not meet these requirements then the monocoque side impact zone must be strengthened
appropriately.
Note: Teams are advised to make an equivalent test with the base line steel tubes such that any
compliance in the test rig can be accounted for.
T3.30.2 If laminates with a lay-up different to that of the side-impact structure are used then additional
physical tests must be completed for any part of the monocoque that forms part of the primary
structure. The material properties derived from these tests must then be used in the SES for the
appropriate equivalency calculations.
Note: A laminate with more or less plies, of the same lay-up as the side-impact structure, does not
constitute a “different lay-up” and the material properties may be scaled accordingly.
T3.30.3 Perimeter shear tests must be completed by measuring the force required to push or pull a 25mm
(1”) diameter flat punch through a flat laminate sample.
48
© 2014 SAE International
Rev. 2 - October 15, 2014
The sample, measuring at least 100mm x 100mm (3.9” x 3.9”), must have core and skin thicknesses
identical to those used in the actual monocoque and be manufactured using the same materials and
processes.
The fixture must support the entire sample, except for a 32mm (1.25”) hole aligned co-axially with
the punch. The sample must not be clamped to the fixture.
The force-displacement data and photos of the test setup must be included in the SES.
The first peak in the load-deflection curve must be used to determine the skin shear strength. This
may be less than the minimum force required by T3.32.3/T3.33.3.
The maximum force recorded must meet the requirements of T3.32.3/T3.33.3.
Note: The edge of the punch and hole in the fixture may include an optional fillet up-to a maximum
radius of 1mm (0.040”).
T3.31
Monocoque Front Bulkhead
See Rule T3.27 for general requirements that apply to all aspects of the monocoque. In addition
when modeled as an “L” shaped section the EI of the front bulkhead about both vertical and lateral
axis must be equivalent to that of the tubes specified for the front bulkhead under T3.18. The length
of the section perpendicular to the bulkhead may be a maximum of 25.4mm (1”) measured from the
rearmost face of the bulkhead.
Furthermore any front bulkhead which supports the IA plate must have a perimeter shear strength
equivalent to a 1.5 mm thick steel plate.
T3.32
Monocoque Front Bulkhead Support
T3.32.1 In addition to proving that the strength of the monocoque is adequate, the monocoque must have
equivalent EI to the sum of the EI of the six (6) baseline steel tubes that it replaces.
T3.32.2 The EI of the vertical side of the front bulkhead support structure must be equivalent to at least the
EI of one baseline steel tube that it replaces when calculated as per rule T3.29 Monocoque Buckling
Modulus.
T3.32.3 The perimeter shear strength of the monocoque laminate in the front bulkhead support structure
should be at least 4kN (880 pounds) for a section with a diameter of 25 mm (1 inch). This must be
proven by a physical test completed as per T3.30.3 and the results include in the SES
T3.33
Monocoque Side Impact
T3.33.1 In addition to proving that the strength of the monocoque is adequate, the side of the monocoque
must have equivalent EI to the sum of the EI of the three (3) baseline steel tubes that it replaces.
T3.33.2 The side of the monocoque between the upper surface of the floor and 350 mm (13.8 inches) above
the ground (Side Impact Zone) must have an EI of at least 50% of the sum of the EI of the three (3)
baseline steel tubes that it replaces when calculated as per Rule T3.29 Monocoque Buckling
Modulus.
T3.33.3 The perimeter shear strength of the monocoque laminate should be at least 7.5 kN (1700 pounds) for
a section with a diameter of 25 mm (1 inch). This must be proven by physical test completed as per
T3.30.3 and the results included in the SES.
49
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 12 – Side Impact Zone Definition for a Monocoque
T3.34
Monocoque Main Hoop
T3.34.1 The Main Hoop must be constructed of a single piece of uncut, continuous, closed section steel
tubing per T3.3.1 and extend down to the bottom of the monocoque.
T3.34.2 The Main Hoop must be mechanically attached at the top and bottom of the monocoque and at
intermediate locations as needed to show equivalency.
T3.34.3 Mounting plates welded to the Roll Hoop shall be at least 2.0 mm (0.080 inch) thick steel.
T3.34.4 Attachment of the Main Hoop to the monocoque must comply with T3.39.
T3.35
Monocoque Front Hoop
T3.35.1 Composite materials are not allowed for the front hoop. See Rule T3.27 for general requirements
that apply to all aspects of the monocoque.
T3.35.2 Attachment of the Front Hoop to the monocoque must comply with Rule T3.39.
T3.36
Monocoque Front and Main Hoop Bracing
T3.36.1 See Rule T3.27 for general requirements that apply to all aspects of the monocoque.
T3.36.2 Attachment of tubular Front or Main Hoop Bracing to the monocoque must comply with Rule
T3.39.
T3.37
Monocoque Impact Attenuator Attachment
The attachment of the Impact Attenuator to a monocoque structure requires an approved “Structural
Equivalency Spreadsheet” per Rule T3.8 that shows the equivalency to a minimum of four (4) 8 mm
Metric Grade 8.8 (5/16 inch SAE Grade 5) bolts.
T3.38
Monocoque Impact Attenuator Anti-intrusion Plate
See Rule T3.27 for general requirements that apply to all aspects of the monocoque and Rule
T3.20.6 for alternate anti-intrusion plate designs.
T3.39
Monocoque Attachments
T3.39.1 In any direction, each attachment point between the monocoque and the other primary structure
must be able to carry a load of 30kN.
50
© 2014 SAE International
Rev. 2 - October 15, 2014
T3.39.2 The laminate, mounting plates, backing plates and inserts must have sufficient shear area, weld area
and strength to carry the specified 30kN load in any direction. Data obtained from the laminate
perimeter shear strength test (T3.33.3) should be used to prove adequate shear area is provided
T3.39.3 Each attachment point requires a minimum of two (2) 8 mm Metric Grade 8.8 (5/16 inch SAE
Grade 5) bolts
T3.39.4 Each attachment point requires steel backing plates with a minimum thickness of 2 mm. Alternate
materials may be used for backing plates if equivalency is approved.
T3.39.5 The Front Hoop Bracing, Main Hoop Bracing and Main Hoop Bracing Supports only may use one
(1) 10 mm Metric Grade 8.8 (3/8 inch SAE Grade 5) bolt as an alternative to T3.39.3 if the bolt is
on the centerline of tube similar to the figure below.
Figure 13 – Alternate Single Bolt Attachment
T3.39.6 No crushing of the core is permitted
T3.39.7 Main Hoop bracing attached to a monocoque (i.e. not welded to a rear space frame) is always
considered “mechanically attached” and must comply with Rule T3.16.
T3.40
Monocoque Driver’s Harness Attachment Points
T3.40.1 The monocoque attachment points for the shoulder and lap belts must support a load of 13 kN
(~3000 pounds) before failure.
T3.40.2 The monocoque attachment points for the ant-submarine belts must support a load of 6.5 kN (~1500
pounds) before failure.
T3.40.3 If the lap belts and anti-submarine belts are attached to the same attachment point, then this point
must support a load of 19.5 kN (~4500 pounds) before failure.
T3.40.4 The strength of lap belt attachment and shoulder belt attachment must be proven by physical test
where the required load is applied to a representative attachment point where the proposed layup
and attachment bracket is used.
ARTICLE T4
COCKPIT
T4.1
Cockpit Opening
T4.1.1
In order to ensure that the opening giving access to the cockpit is of adequate size, a template shown
in Figure 14 will be inserted into the cockpit opening. It will be held horizontally and inserted
vertically until it has passed below the top bar of the Side Impact Structure (or until it is 350 mm
51
© 2014 SAE International
Rev. 2 - October 15, 2014
(13.8 inches) above the ground for monocoque cars). No fore and aft translation of the template
will be permitted during insertion.
Figure 14 – Cockpit Opening Template
T4.1.2
During this test, the steering wheel, steering column, seat and all padding may be removed. The
shifter or shift mechanism may not be removed unless it is integral with the steering wheel and is
removed with the steering wheel. The firewall may not be moved or removed.
Note: As a practical matter, for the checks, the steering column will not be removed. The technical
inspectors will maneuver the template around the steering column shaft, but not the steering column
supports.
T4.2
Cockpit Internal Cross Section:
T4.2.1
A free vertical cross section, which allows the template shown in Figure 15 to be passed
horizontally through the cockpit to a point 100 mm (4 inches) rearwards of the face of the rearmost
pedal when in the inoperative position, must be maintained over its entire length. If the pedals are
adjustable, they will be put in their most forward position.
52
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 15 – Cockpit Internal Cross Section Template
T4.2.2
The template, with maximum thickness of 7mm (0.275 inch), will be held vertically and inserted
into the cockpit opening rearward of the Front Roll Hoop, as close to the Front Roll Hoop as the
car’s design will allow.
T4.2.3
The only items that may be removed for this test are the steering wheel, and any padding required
by Rule T5.8 “Driver’s Leg Protection” that can be easily removed without the use of tools with the
driver in the seat. The seat may not be removed.
T4.2.4
Teams whose cars do not comply with T4.1 or T4.2 will not be given a Technical Inspection Sticker
and will not be allowed to compete in the dynamic events.
Note: Cables, wires, hoses, tubes, etc. must not impede the passage of the templates required by
T4.1 and T4.2.
T4.3
Driver’s Seat
T4.3.1
The lowest point of the driver’s seat must be no lower than the bottom surface of the lower frame
rails or by having a longitudinal tube (or tubes) that meets the requirements for Side Impact tubing,
passing underneath the lowest point of the seat.
T4.3.2
When seated in the normal driving position, adequate heat insulation must be provided to ensure
that the driver will not contact any metal or other materials which may become heated to a surface
temperature above sixty degrees C (60°C). The insulation may be external to the cockpit or
incorporated with the driver’s seat or firewall. The design must show evidence of addressing all
three (3) types of heat transfer, namely conduction, convection and radiation, with the following
between the heat source, e.g. an exhaust pipe or coolant hose/tube and the panel that the driver could
contact, e.g. the seat or floor:
(a) Conduction Isolation by:
53
© 2014 SAE International
Rev. 2 - October 15, 2014
(i)
No direct contact between the heat source and the panel, or
(ii) a heat resistant, conduction isolation material with a minimum thickness of 8 mm
(0.3inch) between the heat source and the panel.
(b) Convection Isolation by a minimum air gap of 25 mm (1 inch) between the heat source and the
panel.
(c) Radiation Isolation by:
(i)
A solid metal heat shield with a minimum thickness of 0.4 mm (0.015inch) or
(ii) reflective foil or tape when combined with T4.3.2(a)(ii) above.
T4.4
Floor Close-out
All vehicles must have a floor closeout made of one or more panels, which separate the driver from
the pavement. If multiple panels are used, gaps between panels are not to exceed 3 mm (1/8 inch).
The closeout must extend from the foot area to the firewall and prevent track debris from entering
the car. The panels must be made of a solid, non-brittle material.
T4.5
Firewall
T4.5.1
Firewall(s) must separate the driver compartment from the following components:
(a) Fuel Tanks.
(b) Accumulators.
(c) All components of the fuel supply.
(d) External engine oil systems including hoses, oil coolers, tanks, etc.
(e) Liquid cooling systems including those for I.C. engine and electrical components.
(f) Lithium-based GLV batteries.
(g) All tractive systems (TS) components
(h) All conductors carrying tractive system voltages (TSV) (Whether contained within conduit or
not.)
Note: T4.5.1(g) and T4.5.1(h) were formerly the “No HV in the cockpit” rule.
T4.5.2
The firewall(s) must be a rigid, non-permeable surface made from 1.5 mm (0.059 inch) or thicker
aluminum or proven equivalent. See Appendix J – Firewall Equivalency Test.
T4.5.3
The firewall(s) must seal completely against the passage of fluids and hot gasses, including at the
sides and the floor of the cockpit, e.g. there can be no holes in a firewall through which seat belts
pass.
T4.5.4
Pass-throughs for GLV wiring, cables, etc. are allowable if grommets are used to seal the passthroughs.
Multiple panels may be used to form the firewall but must be mechanically fastened in place and
sealed at the joints.
T4.5.5
For those components listed in T4.5.1 that are mounted behind the driver, the firewall(s) must
extend sufficiently far upwards and/or rearwards such that a straight line from any part of any listed
component to any part of the tallest driver that is more than 150 mm (6 inches) below the top of
his/her helmet, must pass through the firewall.
T4.5.6
For those components listed in section T4.5.1 positioned under the driver, the firewall must extend:
54
© 2014 SAE International
Rev. 2 - October 15, 2014
(a) Continuously rearwards the full width of the cockpit from the Front Bulkhead, under and up
behind the driver to a point where the helmet of the 95th percentile male template (T3.9.4)
touches the head restraint, and
(b) Alongside the driver, from the top of the Side Impact Structure down to the lower portion of the
firewall required by T4.5.6(a) and from the rearmost front suspension mounting point to
connect (without holes or gaps) behind the driver with the firewall required by T4.5.6(a).
See Figure 16(a).
T4.5.7
For those components listed in section T4.5.1 that are mounted outboard of the Side Impact System
(e.g. in side pods), the firewall(s) must extend from 100 mm (4 inches) forward to 100 mm (4
inches) rearward of the of the listed components and
(a) alongside the driver at the full height of the listed component, and
(b) cover the top of the listed components and
(c) run either
(i) under the cockpit between the firewall(s) required by T4.5.7(a), or
(ii) extend 100 mm (4 inches) out under the listed components from the firewall(s) that are
required by T4.5.8(b)
See Figure 16(b&c).
T4.5.8
For the components listed in section T4.5.1 that are mounted in ways that do not fall clearly under
any of sections T4.5.5, T4.5.6 or T4.5.7, the firewall must be configured to provide equivalent
protection to the driver, and the firewall configuration must be approved by the Rules Committee.
Note: To ensure adequate time for consideration and possible re-designs, applications should be
submitted at least 1 month in advance of the event.
55
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 16 – Examples4 of firewall configurations
T4.6
Accessibility of Controls
All vehicle controls, including the shifter, must be operated from inside the cockpit without any part
of the driver, e.g. hands, arms or elbows, being outside the planes of the Side Impact Structure
defined in Rule T3.24 and T3.33.
T4.7
Driver Visibility
T4.7.1
The driver must have adequate visibility to the front and sides of the car. With the driver seated in a
normal driving position he/she must have a minimum field of vision of two hundred degrees (200°)
(a minimum one hundred degrees (100°) to either side of the driver). The required visibility may be
obtained by the driver turning his/her head and/or the use of mirrors.
T4.7.2
If mirrors are required to meet Rule T4.7.1, they must remain in place and adjusted to enable the
required visibility throughout all dynamic events.
T4.8
Driver Egress
All drivers must be able to exit to the side of the vehicle in no more than 5 seconds. Egress time
begins with the driver in the fully seated position, hands in driving position on the connected
4
The firewalls shown in red in Figure 16 are examples only and are not meant to imply that a firewall must lie outside
the frame rails.
56
© 2014 SAE International
Rev. 2 - October 15, 2014
steering wheel and wearing the required driver equipment. Egress time will stop when the driver has
both feet on the pavement.
T4.9
Emergency Shut Down Test
T4.9.1
With their vision obscured, all drivers must be able to operate the cockpit Big Red Button (BRB) in
no more than one second.
T4.9.2
Time begins with the driver in the fully seated position, hands in driving position on the connected
steering wheel, and wearing the required driver equipment.
ARTICLE T5
DRIVERS EQUIPMENT (BELTS AND COCKPIT PADDING)
T5.1
Belts - General
T5.1.1
Definitions
(a) 5-point system – consists of a 76 mm (3 inch) wide lap belt, approximately 76 mm (3 inch)
wide shoulder straps and a single approximately 51 mm (2 inch) wide anti-submarine strap.
The single anti-submarine strap must have a metal-to-metal connection with the single release
common to the lap belt and shoulder harness.
(b) 6-point system – consists of a 76 mm (3 inch) wide lap belt, approximately 76 mm (3 inch)
wide shoulder straps and two (2) approximately 51 mm (2 inch) wide leg or anti-submarine
straps.
(c) 7-point system – system is the same as the 6-point except it has three (3) anti-submarine
straps, two (2) from the 6-point system and one (1) from the 5-point system.
Note: 6 and 7-point harnesses to FIA specification 8853/98 and SFI Specification 16.5 with
approximately 51 mm (2 inch) lap belts are acceptable.
(d) Upright driving position - is defined as one with a seat back angled at thirty degrees (30°) or
less from the vertical as measured along the line joining the two 200 mm circles of the template
of the 95th percentile male as defined in Table 7 and positioned per T3.9.4.
(e) Reclined driving position - is defined as one with a seat back angled at more than thirty
degrees (30°) from the vertical as measured along the line joining the two 200 mm circles of
the template of the 95th percentile male as defined in Table 7 and positioned per T3.9.4.
(f)
T5.1.2
Chest-groin line - is the straight line that in side view follows the line of the shoulder belts
from the chest to the release buckle.
Harness Requirements
All drivers must use a 5, 6 or 7 point restraint harness meeting the following specifications:
(a) All driver restraint systems must meet SFI Specification 16.1, SFI Specification 16.5, or FIA
specification 8853/98.
(b) The belts must bear the appropriate dated labels.
(c) The material of all straps must be in perfect condition.
(d) There must be a single release common to the lap belt and shoulder harness using a metal-tometal quick release type latch.
(e) To accommodate drivers of differing builds, all lap belts must have a “tilt-lock adjuster”
feature. Lap belts with “pull-up” adjusters are recommended over “pull-down” adjusters.
57
© 2014 SAE International
Rev. 2 - October 15, 2014
(f)
Cars with a “reclined driving position” (see T5.1.1(e) above) must have either a 6 point or 7point harness, and have either anti-submarine belts with “tilt-lock adjusters” or have two (2)
sets of anti-submarine belts installed.
(g) The shoulder harness must be the over-the-shoulder type. Only separate shoulder straps are
permitted (i.e. “Y”-type shoulder straps are not allowed). The “H”-type configuration is
allowed.
(h) It is mandatory that the shoulder harness, where it passes over the shoulders, be 76 mm (3 inch)
wide, except as noted below. The shoulder harness straps must be threaded through the three
bar adjusters in accordance with manufacturer’s instructions.
(i)
When the HANS device is used by the driver, FIA certified 51 mm (2 inch) wide shoulder
harnesses are allowed. Should a driver, at any time not utilize the HANS device, then 76 mm
(3 inch) wide shoulder harnesses are required.
T5.1.3
Harness Replacement - SFI spec harnesses must be replaced following December 31st of the 2nd year
after the date of manufacture as indicated by the label. FIA spec harnesses must be replaced
following December 31st of the year marked on the label. (Note: FIA belts are normally certified for
five (5) years from the date of manufacture.)
T5.1.4
The restraint system must be worn tightly at all times.
T5.2
Belt, Strap and Harness Installation - General
T5.2.1
The lap belt, shoulder harness and anti-submarine strap(s) must be securely mounted to the Primary
Structure. Such structure and any guide or support for the belts must meet the minimum
requirements of T3.3.1.
Note: Rule T3.4.5 applies to these tubes as well so a non-straight shoulder harness bar would
require support per T3.4.5
T5.2.2
The tab to which any harness is attached must have:
(a) A minimum cross sectional area of 40 sq. mm (0.062 sq. inch) of steel to be sheared or failed
in tension at any point of the tab, and
(b) A minimum thickness of 1.6 mm (0.063 inch).
(c) Where lap belts and anti-submarine belts use the same attachment point, a minimum cross
sectional area of 90 sq. mm (0.140 sq. inch) of steel to be sheared if failed in tension at any
point of the tab.
Note: Double shear mounting is preferred.
T5.2.3
Harnesses, belts and straps must not pass through a firewall, i.e. all harness attachment points must
be on the driver’s side of any firewall.
T5.2.4
The attachment of the Driver’s Restraint System to a monocoque structure requires an approved
Structural Equivalency Spreadsheet per Rule T3.8.
T5.2.5
The restraint system installation is subject to approval of the Chief Technical Inspector.
T5.3
Lap Belt Mounting
T5.3.1
The lap belt must pass around the pelvic area below the Anterior Superior Iliac Spines (the hip
bones).
T5.3.2
The lap belts should not be routed over the sides of the seat. The lap belts should come through the
seat at the bottom of the sides of the seat to maximize the wrap of the pelvic surface and continue in
a straight line to the anchorage point.
58
© 2014 SAE International
Rev. 2 - October 15, 2014
T5.3.3
Where the belts or harness pass through a hole in the seat, the seat must be rolled or grommeted to
prevent chafing of the belts.
T5.3.4
To fit drivers of differing statures correctly, in side view, the lap belt must be capable of pivoting
freely by using either a shouldered bolt or an eye bolt attachment, i.e. mounting lap belts by
wrapping them around frame tubes is no longer acceptable.
T5.3.5
With an “upright driving position”, in side view the lap belt must be at an angle of between fortyfive degrees (45°) and sixty-five degrees (65°) to the horizontal. This means that the centerline of
the lap belt at the seat bottom should be between 0 – 76 mm (0 – 3 inches) forward of the seat back
to seat bottom junction. (See Figure 17)
Figure 17 – Lap Belt Angles with Upright Driver
T5.3.6
With a “reclined driving position”, in side view the lap belt must be between an angle of sixty
degrees (60°) and eighty degrees (80°) to the horizontal.
T5.4
Shoulder Harness
T5.4.1
The shoulder harness must be mounted behind the driver to structure that meets the requirements of
T3.3.1. However, it cannot be mounted to the Main Roll Hoop Bracing or attendant structure
without additional bracing to prevent loads being transferred into the Main Hoop Bracing.
T5.4.2
If the harness is mounted to a tube that is not straight, the joints between this tube and the structure
to which it is mounted must be reinforced in side view by gussets or triangulation tubes to prevent
torsional rotation of the harness mounting tube.
T5.4.3
The shoulder harness mounting points must be between 178 mm (7 inches) and 229 mm (9 inches)
apart. (See Figure 18)
59
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 18 – Shoulder Harness Mounting – Top View
T5.4.4
From the driver’s shoulders rearwards to the mounting point or structural guide, the shoulder
harness must be between ten degrees (10°) above the horizontal and twenty degrees (20°) below the
horizontal. (See Figure 19).
Figure 19 - Shoulder Harness Mounting – Side View
T5.5
Anti-Submarine Belt Mounting
T5.5.1
The anti-submarine belt of a 5 point harness should be mounted in line with, or angled slightly
forward (up to twenty degrees (20°)) of, the driver’s chest-groin line.
T5.5.2
The anti-submarine belts of a 6 point harness should be mounted either:
(a) With the belts going vertically down from the groin, or angled up to twenty degrees (20°)
rearwards. The anchorage points should be approximately 100 mm (4 inches) apart. Or
(b) With the anchorage points on the Primary Structure at or near the lap belt anchorages, the
driver sitting on the anti-submarine belts, and the belts coming up around the groin to the
release buckle.
T5.6
Head Restraint
T5.6.1
A head restraint must be provided on the car to limit the rearward motion of the driver’s head.
60
© 2014 SAE International
Rev. 2 - October 15, 2014
T5.6.2
The restraint must:
(a) Be vertical or near vertical in side view.
(b) Be padded with an energy absorbing material such as Ethafoam® or Ensolite® with a
minimum thickness of 38 mm (1.5 inches).
(c) Have a minimum width of 15 cm (6 inch).
(d) Have a minimum area of 235 sq. cm (36 sq. inch) AND have a minimum height adjustment of
17.5 cm (7 inches), OR have a minimum height of 28 cm (11 inches).
(e) Be located so that for each driver:
(i) The restraint is no more than 25 mm (1 inch) away from the back of the driver’s helmet,
with the driver in their normal driving position.
(ii) The contact point of the back of the driver’s helmet on the head restraint is no less than 50
mm (2 inch) from any edge of the head restraint.
Note 1: Head restraints may be changed to accommodate different drivers (See T1.2.2(d))
Note 2: The above requirements must be met for all drivers.
Note 3: Approximately 100mm (4”) longitudinal adjustment is required to accommodate 5th to 95th
Percentile drivers. This is not a specific rules requirement, but teams must have sufficient
longitudinal adjustment and/or alternative thickness head restraints available, such that the above
requirements are met by all their drivers.
T5.6.3
The restraint, its attachment and mounting must be strong enough to withstand a force of 890
Newtons (200 lbs. force) applied in a rearward direction.
T5.7
Roll Bar Padding
Any portion of the roll bar, roll bar bracing or frame which might be contacted by the driver’s
helmet must be covered with a minimum thickness of 12 mm (0.5 inch) of padding which meets SFI
spec 45.1 or FIA 8857-2001.
T5.8
Driver’s Leg Protection
T5.8.1
To keep the driver’s legs away from moving or sharp components, all moving suspension and
steering components, and other sharp edges inside the cockpit between the front roll hoop and a
vertical plane 100 mm (4 inches) rearward of the pedals, must be shielded with a shield made of a
solid material. Moving components include, but are not limited to springs, shock absorbers, rocker
arms, anti-roll/sway bars, steering racks and steering column CV joints.
T5.8.2
Covers over suspension and steering components must be removable to allow inspection of the
mounting points.
ARTICLE T6
GENERAL CHASSIS RULES
T6.1
Suspension
T6.1.1
The car must be equipped with a fully operational suspension system with shock absorbers, front
and rear, with usable wheel travel of at least 50.8 mm (2 inches), 25.4 mm (1 inch) jounce and 25.4
mm (1 inch) rebound, with driver seated. The judges reserve the right to disqualify cars which do
not represent a serious attempt at an operational suspension system or which demonstrate handling
inappropriate for an autocross circuit.
61
© 2014 SAE International
Rev. 2 - October 15, 2014
T6.1.2
All suspension mounting points must be visible at Technical Inspection, either by direct view or by
removing any covers.
T6.2
Ground Clearance
The ground clearance must be sufficient to prevent any portion of the car (other than tires) from
touching the ground during track events, and with the driver aboard there must be a minimum of
25.4 mm (1 inch) of static ground clearance under the complete car at all times.
T6.3
Wheels
T6.3.1
The wheels of the car must be 203.2 mm (8.0 inches) or more in diameter.
T6.3.2
Any wheel mounting system that uses a single retaining nut must incorporate a device to retain the
nut and the wheel in the event that the nut loosens. A second nut (“jam nut”) does not meet these
requirements.
T6.3.3
Standard wheel lug bolts are considered engineering fasteners and any modification will be subject
to extra scrutiny during technical inspection. Teams using modified lug bolts or custom designs
will be required to provide proof that good engineering practices have been followed in their design.
T6.3.4
Aluminum wheel nuts may be used, but they must be hard anodized and in pristine condition.
T6.4
Tires
T6.4.1
Vehicles may have two types of tires as follows:
(a) Dry Tires – The tires on the vehicle when it is presented for technical inspection are defined as
its “Dry Tires”. The dry tires may be any size or type. They may be slicks or treaded.
(b) Rain Tires – Rain tires may be any size or type of treaded or grooved tire provided:
(i)
The tread pattern or grooves were molded in by the tire manufacturer, or were cut by the
tire manufacturer or his appointed agent. Any grooves that have been cut must have
documentary proof that it was done in accordance with these rules.
(ii) There is a minimum tread depth of 2.4 mms (3/32 inch).
Note: Hand cutting, grooving or modification of the tires by the teams is specifically prohibited.
T6.4.2
Within each tire set, the tire compound or size, or wheel type or size may not be changed after static
judging has begun. Tire warmers are not allowed. No traction enhancers may be applied to the tires
after the static judging has begun.
T6.5
Steering
T6.5.1
The steering wheel must be mechanically connected to the wheels, i.e. “steer-by-wire” or
electrically actuated steering is prohibited.
T6.5.2
The steering system must have positive steering stops that prevent the steering linkages from
locking up (the inversion of a four-bar linkage at one of the pivots). The stops may be placed on the
uprights or on the rack and must prevent the tires from contacting suspension, body, or frame
members during the track events.
T6.5.3
Allowable steering system free play is limited to seven degrees (7°) total measured at the steering
wheel.
T6.5.4
The steering wheel must be attached to the column with a quick disconnect. The driver must be able
to operate the quick disconnect while in the normal driving position with gloves on.
T6.5.5
The steering wheel must have a continuous perimeter that is near circular or near oval, i.e. the outer
perimeter profile can have some straight sections, but no concave sections. “H”, “Figure 8”, or
cutout wheels are not allowed.
62
© 2014 SAE International
Rev. 2 - October 15, 2014
T6.5.6
In any angular position, the top of the steering wheel must be no higher than the top-most surface of
the Front Hoop. See Figure 7.
T6.5.7
Steering systems using cables for actuation are not prohibited by T6.5.1 but additional
documentation must be submitted. The team must submit a failure modes and effects analysis
report with design details of the proposed system as part of the structural equivalency spreadsheet
(SES).
The report must outline the analysis that was done to show the steering system will function
properly, potential failure modes and the effects of each failure mode and finally failure mitigation
strategies used by the team. The organizing committee will review the submission and advise the
team if the design is approved. If not approved, a non-cable based steering system must be used
instead.
T6.6
Jacking Point
T6.6.1
A jacking point, which is capable of supporting the car’s weight and of engaging the organizers’
“quick jacks”, must be provided at the rear of the car.
T6.6.2
The jacking point is required to be:
(a) Visible to a person standing 1 meter (3 feet) behind the car.
(b) Painted orange.
(c) Oriented horizontally and perpendicular to the centerline of the car
(d) Made from round, 25 – 29 mm (1 – 1 1/8 inch) O.D. aluminum or steel tube
(e) A minimum of 300 mm (12 inches) long
(f)
Exposed around the lower 180 degrees (180°) of its circumference over a minimum length of
280 mm (11 inches)
(g) The height of the tube is required to be such that:
(i)
There is a minimum of 75 mm (3 inches) clearance from the bottom of the tube to the
ground measured at tech inspection.
(ii) With the bottom of the tube 200 mm (7.9 inches) above ground, the wheels do not touch
the ground when they are in full rebound.
Comment on Disabled Cars – The organizers and the Rules Committee remind teams that cars
disabled on course must be removed as quickly as possible. A variety of tools may be used to move
disabled cars including quick jacks, dollies of different types, tow ropes and occasionally even
boards. We expect cars to be strong enough to be easily moved without damage. Speed is
important in clearing the course and although the course crew exercises due care, parts of a vehicle
can be damaged during removal. The organizers are not responsible for damage that occurs when
moving disabled vehicles. Removal/recovery workers will jack, lift, carry or tow the car at
whatever points they find easiest to access. Accordingly, we advise teams to consider the strength
and location of all obvious jacking, lifting and towing points during the design process.
T6.7
Rollover Stability
T6.7.1
The track and center of gravity of the car must combine to provide adequate rollover stability.
T6.7.2
Rollover stability will be evaluated on a tilt table using a pass/fail test. The vehicle must not roll
when tilted at an angle of sixty degrees (60°) to the horizontal in either direction, corresponding to
1.7 G’s. The tilt test will be conducted with the tallest driver in the normal driving position.
63
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE T7
BRAKE SYSTEM
T7.1
Brake System - General
T7.1.1
The car must be equipped with a braking system that acts on all four wheels and is operated by a
single control.
T7.1.2
It must have two (2) independent hydraulic circuits such that in the case of a leak or failure at any
point in the system, effective braking power is maintained on at least two (2) wheels. Each hydraulic
circuit must have its own fluid reserve, either by the use of separate reservoirs or by the use of a
dammed, OEM-style reservoir.
T7.1.3
A single brake acting on a limited-slip differential is acceptable.
T7.1.4
The brake system must be capable of locking all four (4) wheels during the test specified in section
T7.2.
T7.1.5
“Brake-by-wire” systems are prohibited.
T7.1.6
Unarmored plastic brake lines are prohibited.
T7.1.7
The braking systems must be protected with scatter shields from failure of the drive train (see T8.4)
or from minor collisions.
T7.1.8
In side view no portion of the brake system that is mounted on the sprung part of the car can project
below the lower surface of the frame or the monocoque, whichever is applicable.
T7.1.9
The brake pedal shall be designed to withstand a force of 2000 N without any failure of the brake
system or pedal box. This may be tested by pressing the pedal with the maximum force that can be
exerted by any official when seated normally.
T7.1.10 The brake pedal must be fabricated from steel or aluminum or machined from steel, aluminum or
titanium.
T7.1.11 The first 50% of the brake pedal travel may be used to control regeneration without necessarily
actuating the hydraulic brake system.
The remaining brake pedal travel must directly actuate the hydraulic brake system, but brake energy
regeneration may remain active.
Note: Any strategy to regenerate energy while coasting or braking must be covered by the FMEA /
ESF.
T7.2
Brake Test
T7.2.1
The brake system will be dynamically tested and must demonstrate the capability of locking all four
(4) wheels and stopping the vehicle in a straight line at the end of an acceleration run specified by
the brake inspectors.
T7.2.2
After accelerating, the tractive system must be switched off by the driver and the driver has to lock
all four wheels of the vehicle by braking. The brake test is passed if all four wheels simultaneously
lock while the tractive system is shut down.
Note: It is acceptable if the Tractive System Active Light switches off shortly after the vehicle has
come to a complete stop as the reduction of the system voltage may take up to 5 seconds.
T7.3
Brake Over-Travel Switch
T7.3.1
A brake pedal over-travel switch must be installed on the car as part of the shutdown system and
wired in series with the shutdown buttons. This switch must be installed so that in the event of brake
64
© 2014 SAE International
Rev. 2 - October 15, 2014
system failure such that the brake pedal over travels it will result in the shutdown system being
activated and controlling the systems as defined in EV5.4 and Table 17.
T7.3.2
Repeated actuation of the switch must not restore power to these components, and it must be
designed so that the driver cannot reset it.
T7.3.3
The brake over-travel switch must not be used as a mechanical stop for the brake pedal and must be
installed in such a way that it and its mounting will be intact and operational when actuated.
T7.3.4
The switch must be implemented with analog components, and not through recourse to
programmable logic controllers, engine control units, or similar functioning digital controllers.
T7.3.5
The Brake Over-Travel switch must be a mechanical single pole, single throw (commonly known as
a two-position) switch (push-pull or flip type) as shown below.
Figure 20 – Over-travel Switches
T7.4
Brake Light
T7.4.1
The car must be equipped with a red brake light. The brake light itself must be rectangular,
triangular or near round shape with a minimum shining surface of at least 15cm². Each brake light
must be clearly visible from the rear in very bright sunlight.
T7.4.2
This light must be mounted between the wheel centerline and driver’s shoulder level vertically and
approximately on vehicle centerline laterally.
ARTICLE T8
POWERTRAIN
T8.1
Coolant Fluid Limitations
T8.1.1
Water-cooled engines must use only plain water. Glycol-based antifreeze, “water wetter”, water
pump lubricants of any kind, or any other additives are strictly prohibited.
T8.1.2
Electric motors, accumulators or electronics can use plain water or approved5 fluids as the coolant.
T8.2
System Sealing
T8.2.1
Any cooling or lubrication system must be sealed to prevent leakage.
5
Contact the organizers for approval of fluids other than water.
65
© 2014 SAE International
Rev. 2 - October 15, 2014
T8.2.2
Separate catch cans must be employed to retain fluids from any vents for the coolant system or
lubrication system. Each catch-can must have a minimum volume of ten (10) percent of the fluid
being contained or 0.9 liter (one U.S. quart) whichever is greater.
T8.2.3
Catch cans must be capable of containing boiling water without deformation, and be located
rearwards of the firewall below driver’s shoulder level, and be positively retained, i.e. no tie-wraps
or tape.
T8.2.4
Any catch can on the cooling system must vent through a hose with a minimum internal diameter of
3 mm (1/8 inch) down to the bottom levels of the Frame.
T8.3
Transmission and Drive
Any transmission may be used.
T8.4
Drive Train Shields and Guards
T8.4.1
Exposed high-speed final drivetrain equipment such as Continuously Variable Transmissions
(CVTs), sprockets, gears, pulleys, torque converters, clutches, belt drives and clutch drives, must be
fitted with scatter shields in case of failure. The final drivetrain shield must cover the chain or belt
from the drive sprocket to the driven sprocket/chain wheel/belt or pulley. The final drivetrain shield
must start and end parallel to the lowest point of the chain wheel/belt/pulley. (See Figure 21) Body
panels or other existing covers are not acceptable unless constructed from approved materials per
T8.4.3 or T8.4.4.
Note: If equipped, the engine drive sprocket cover may be used as part of the scatter shield system.
Figure 21 - Final Drive Scatter Shield Example
Comment: Scatter shields are intended to contain drivetrain parts which might separate from the
car.
T8.4.2
Perforated material may not be used for the construction of scatter shields.
66
© 2014 SAE International
Rev. 2 - October 15, 2014
T8.4.3
Chain Drive - Scatter shields for chains must be made of at least 2.66 mm (0.105 inch) steel (no
alternatives are allowed), and have a minimum width equal to three (3) times the width of the chain.
The guard must be centered on the center line of the chain and remain aligned with the chain under
all conditions.
T8.4.4
Non-metallic Belt Drive - Scatter shields for belts must be made from at least 3.0 mm (0.120 inch)
Aluminum Alloy 6061-T6, and have a minimum width that is equal to 1.7 times the width of the
belt.
T8.4.5
The guard must be centered on the center line of the belt and remain aligned with the belt under all
conditions.
T8.4.6
Attachment Fasteners - All fasteners attaching scatter shields and guards must be a minimum 6mm
Metric Grade 8.8 (1/4 inch SAE Grade 5) or stronger.
T8.4.7
Finger Guards – Finger guards are required to cover any drivetrain parts that spin while the car is
stationary with the engine running. Finger guards may be made of lighter material, sufficient to
resist finger forces. Mesh or perforated material may be used but must prevent the passage of a 12
mm (1/2 inch) diameter object through the guard.
Comment: Finger guards are intended to prevent finger intrusion into rotating equipment while the
vehicle is at rest.
T8.5
Integrity of systems carrying fluids – Tilt Test
T8.5.1
During technical inspection, the car must be capable of being tilted to a forty-five degree (45°) angle
without leaking fluid of any type.
T8.5.2
The tilt test will be conducted with the vehicle containing the maximum amount of fluids it will
carry during any test or event.
ARTICLE T9
T9.1
AERODYNAMIC DEVICES
Aero Dynamics and Ground Effects - General
All aerodynamic devices must satisfy the following requirements:
T9.2
Location
In plan view, no part of any aerodynamic device, wing, under tray or splitter can be:
(a) Further forward than 460 mm (18 inches) forward of the fronts of the front tires
(b) No further rearward than the rear of the rear tires.
(c) No wider than the outside of the front tires or rear tires measured at the height of the hubs,
whichever is wider.
T9.3
Wing Edges - Minimum Radii
All wing leading edges must have a minimum radius 12.7 mm (0.5 inch). Wing leading edges must
be as blunt or blunter than the required radii for an arc of plus or minus 45 degrees (± 45°) centered
on a plane parallel to the ground or similar reference plane for all incidence angles which lie within
the range of adjustment of the wing or wing element. If leading edge slats or slots are used, both the
fronts of the slats or slots and of the main body of the wings must meet the minimum radius rules.
T9.4
Other Edge Radii Limitations
All wing edges, end plates, Gurney flaps, wicker bills, splitters undertrays and any other wing
accessories must have minimum edge radii of at least 3 mm (1/8 inch) i.e., this means at least a 6
mm (1/4 inch) thick edge.
67
© 2014 SAE International
Rev. 2 - October 15, 2014
T9.5
Ground Effect Devices
No power device may be used to move or remove air from under the vehicle except fans designed
exclusively for cooling. Power ground effects are prohibited.
T9.6
Driver Egress Requirements
T9.6.1
Egress from the vehicle within the time set in Rule T4.8 “Driver Egress,” must not require any
movement of the wing or wings or their mountings.
T9.6.2
The wing or wings must be mounted in such positions, and sturdily enough, that any accident is
unlikely to deform the wings or their mountings in such a way to block the driver’s egress.
ARTICLE T10 COMPRESSED GAS SYSTEMS AND HIGH PRESSURE HYDRAULICS
T10.1
Compressed Gas Cylinders and Lines
Any system on the vehicle that uses a compressed gas as an actuating medium must comply with the
following requirements:
(a) Working Gas -The working gas must be nonflammable, e.g. air, nitrogen, carbon dioxide.
(b) Cylinder Certification - The gas cylinder/tank must be of proprietary manufacture, designed
and built for the pressure being used, certified by an accredited testing laboratory in the
country of its origin, and labeled or stamped appropriately.
(c) Pressure Regulation -The pressure regulator must be mounted directly onto the gas
cylinder/tank.
(d) Protection – The gas cylinder/tank and lines must be protected from rollover, collision from
any direction, or damage resulting from the failure of rotating equipment.
(e) Cylinder Location - The gas cylinder/tank and the pressure regulator must be located either
rearward of the Main Roll Hoop and within the envelope defined by the Main Roll Hoop and
the Frame (See T3.2), or in a structural side-pod. In either case it must be protected by
structure that meets the requirements of T3.24 or T3.33. It must not be located in the cockpit.
(f)
Cylinder Mounting - The gas cylinder/tank must be securely mounted to the Frame, engine or
transmission.
(g) Cylinder Axis - The axis of the gas cylinder/tank must not point at the driver.
(h) Insulation - The gas cylinder/tank must be insulated from any heat sources, e.g. the exhaust
system.
(i)
T10.2
Lines and Fittings - The gas lines and fittings must be appropriate for the maximum possible
operating pressure of the system.
High Pressure Hydraulic Pumps and Lines
The driver and anyone standing outside the car must be shielded from any hydraulic pumps and
lines with line pressures of 300 psi (2100 kPa) or higher. The shields must be steel or aluminum
with a minimum thickness of 1 mm (0.039 inch).
Note: Brake lines are not classified as “hydraulic pump lines” and as such brake lines are excluded
from T10.2.
68
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE T11 FASTENERS
T11.1
Fastener Grade Requirements
T11.1.1 All threaded fasteners utilized in the driver’s cell structure, and the steering, braking, driver’s
harness and suspension systems must meet or exceed, SAE Grade 5, Metric Grade 8.8 and/or
AN/MS specifications.
T11.1.2 The use of button head cap, pan head, flat head or round head screws or bolts in ANY location in
the following systems is prohibited:
(a) Driver’s cell structure,
(b) Impact attenuator attachment
(c) Driver’s harness attachment
(d) Steering system
(e) Brake system
(f) Suspension system.
Note: Hexagonal recessed drive screws or bolts (sometimes called Socket head cap screws or Allen
screws/bolts) are permitted.
T11.2
Securing Fasteners
T11.2.1 All critical bolt, nuts, and other fasteners on the steering, braking, driver’s harness, and suspension
must be secured from unintentional loosening by the use of positive locking mechanisms.
Positive locking mechanisms are defined as those that:
(a) The Technical Inspectors (and the team members) are able to see that the device/system is in
place, i.e. it is visible, and
(b) the “positive locking mechanism” does not rely on the clamping force to apply the “locking” or
anti-vibration feature. In other words, if it loosens a bit, it still prevents the nut or bolt coming
completely loose.
See Figure 22
Positive locking mechanisms include:
(c) Correctly installed safety wiring
(d) Cotter pins
(e) Nylon lock nuts
(f)
Prevailing torque lock nuts
Note: Lock washers, bolts with nylon patches, and thread locking compounds, e.g. Loctite®, DO
NOT meet the positive locking requirement.
69
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 22 - Examples of positive locking nuts
T11.2.2 There must be a minimum of two (2) full threads projecting from any lock nut.
T11.2.3 All spherical rod ends and spherical bearings on the steering or suspension must be in double shear
or captured by having a screw/bolt head or washer with an O.D. that is larger than spherical bearing
housing I.D.
T11.2.4 Adjustable tie-rod ends must be constrained with a jam nut to prevent loosening.
ARTICLE T12 TRANSPONDERS
T12.1
Transponders
T12.1.1 Transponders will be used as part of the timing system for the Formula Hybrid competition.
T12.1.2 Each team is responsible for having a functional, properly mounted transponder of the specified
type on their vehicle. Vehicles without a specified transponder will not be allowed to compete in
any event for which a transponder is used for timing and scoring.
T12.1.3 All vehicles must be equipped with at least one MYLAPS Car/Bike Rechargeable Power
Transponder or MYLAPS Car/Bike Direct Power Transponder.
Note 1: Except for their name, AMB TranX260 transponders are identical to MYLAPS Car/Bike
Transponders and fully comply with this rule. If you own a functional AMB TranX260 it does not
need to be replaced.
Note 2: It is the responsibility of the team to ensure that electrical interference from their vehicle
does not stop the transponder from functioning correctly
T12.2
Transponder Mounting – All Events
The transponder mounting requirements are:
70
© 2014 SAE International
Rev. 2 - October 15, 2014
(a) Orientation – The transponder must be mounted vertically and orientated so the number can
be read “right-side up”.
(b) Location – The transponder must be mounted on the driver’s right side of the car forward of
the front roll hoop. The transponder must be no more than 60 cm (24inch) above the track.
(c) Obstructions – There must be an open, unobstructed line between the antenna on the bottom
of the transponder and the ground. Metal and carbon fiber may interrupt the transponder signal.
The signal will normally transmit through fiberglass and plastic. If the signal will be obstructed
by metal or carbon fiber, a 10.2 cm (4inch) diameter opening can be cut, the transponder
mounted flush with the opening, and the opening covered with a material transparent to the
signal.
(d) Protection – Mount the transponder where it will be protected from obstacles.
ARTICLE T13 VEHICLE IDENTIFICATION
T13.1
Car Number
T13.1.1 Each car will be assigned a number at the time of its entry into a competition.
T13.1.2 Car numbers must appear on the vehicle as follows:
(a) Locations: In three (3) locations: the front and both sides;
(b) Height: At least 15.24 cm (6 inch) high;
(c) Font: Block numbers (i.e. sans-serif characters). Italic, outline, serif, shadow, or cursive
numbers are prohibited.
(d) Stroke Width and Spacing between Numbers: At least 2.0 cm (3/4 inch).
(e) Color: Either white numbers on a black background or black numbers on a white background.
No other color combinations will be approved.
(f)
Background shape: The number background must be one of the following: round, oval,
square or rectangular. There must be at least 2.5 cm (1 inch) between the edge of the numbers
and the edge of the background.
(g) Clear: The numbers must not be obscured by parts of the car, e.g. wheels, side pods, exhaust
system, etc.
T13.1.3 Car numbers for teams registered for Formula Hybrid can be found on the “Registered Teams”
section of the SAE Collegiate Design Series website.
Comment: Car numbers must be quickly read by course marshals when your car is moving at
speed. Make your numbers easy to see and easy to read.
Figure 23 - Example Car Number
71
© 2014 SAE International
Rev. 2 - October 15, 2014
T13.2
School Name
T13.2.1 Each car must clearly display the school name (or initials – if unique and generally recognized) in
roman characters at least 5.08 cm, (2 inch) high on both sides of the vehicle. The characters must be
placed on a high contrast background in an easily visible location.
T13.2.2 The school name may also appear in non-roman characters, but the roman character version must be
uppermost on the sides.
T13.3
SAE & IEEE Logos
T13.3.1 SAE and IEEE logos must be prominently displayed on the front and/or both sides of the vehicle.
Each logo must be at least 7.6 cm x 20.3 cm (3 inch x 8 inch).
T13.3.2 The organizers can provide the following decals either by mail or at the competition:
(a) SAE, 7.6 cm x 20.3 cm (3 inch x 8 inch) in either White or Black.
(b) IEEE, 11.4 cm x 30.5 cm (4.5 inch x 12 inch) (Blue and Gold only).
T13.3.3 Actual-size JPEGs may be downloaded from the Formula Hybrid website.
T13.4
Technical Inspection Sticker Space
Technical inspection stickers will be placed on the upper nose of the vehicle. Cars must have a clear
and unobstructed area at least 25.4 cm wide x 20.3cm high (10” x 8”) on the upper front surface of
the nose along the vehicle centerline.
ARTICLE T14 EQUIPMENT REQUIREMENTS
T14.1
Driver’s Equipment
The equipment specified below must be worn by the driver anytime he or she is in the cockpit with
the engine running.
T14.2
Helmet
T14.2.1 A well-fitting, closed face helmet that meets one of the following certifications and is labeled as
such:
(a) Snell K2000, K2005, K2010, M2000, M2005, M2010, SA2000, SA2005, SA2010
(b) SFI 31.2A, SFI 31.1/2005
(c) FIA 8860-2004, FIA 8860-2010
(d) British Standards Institution BS 6658-85 Type A/FR rating (Types A and B are not accepted)
T14.2.2 Open faced helmets are not approved.
T14.2.3 All helmets to be used in the competition must be presented during Technical Inspection where
approved helmets will be stickered. The organizer reserves the right to impound all non-approved
helmets until the end of the competition.
T14.3
Balaclava
A balaclava which covers the driver’s head, hair and neck, made from acceptable fire resistant
material as defined in T14.12, or a full helmet skirt of acceptable fire resistant material. The
balaclava requirement applies to drivers of either gender, with any hair length.
T14.4
Eye Protection
Impact resistant goggles or helmet face shield, made from approved impact resistant materials. The
face shield supplied with approved helmets (See T14.2 above) meets this requirement.
72
© 2014 SAE International
Rev. 2 - October 15, 2014
T14.5
Suit
A fire resistant suit that covers the body from the neck down to the ankles and the wrists. One (1)
piece suits are required. The suit must be in good condition, i.e. it must have no tears or open seams,
or oil stains that could compromise its fire resistant capability. The suit must be certified to one of
the following standards and be labeled as such:
-FIA Standard 8856-1986
-SFI 3-2A/1 but only when used with
fire resistant, e.g. Nomex, underwear
that covers the body from wrist to ankles.
-SFI 3-2A/5 (or higher)
- FIA Standard 8856-2000
Table 8 – SFI / FIA Standards Logos
T14.6
Underclothing
It is strongly recommended that all drivers wear fire resistant underwear (long pants and long sleeve
top) under their approved driving suit. This fire resistant underwear must be made from acceptable
fire resistant material and cover the driver’s body completely from the neck down to the ankles and
wrists.
Note: If drivers do not wear fire resistant long underwear, it is strongly recommended that they wear
cotton underwear under the approved driving suit. Tee-shirts, or other undergarments made from
Nylon or any other synthetic materials may melt when exposed to high heat.
73
© 2014 SAE International
Rev. 2 - October 15, 2014
T14.7
Socks
Socks made from an accepted fire resistant material, e.g. Nomex, which cover the bare skin between
the driver’s suit and the boots or shoes. Socks made from wool or cotton are acceptable. Socks of
nylon or polyester are not acceptable.
T14.8
Shoes
Shoes of durable fire resistant material and which are in good condition (no holes worn in the soles
or uppers).
T14.9
Gloves
Fire resistant gloves made from made from acceptable fire resistant material as defined in T14.12.
Gloves of all leather construction or fire resistant gloves constructed using leather palms with no
insulating fire resisting material underneath are not acceptable.
T14.10
Arm Restraints
Arm restraints certified and labeled to SF1 standard 3.3, or a commercially manufactured
equivalent, must be worn such that the driver can release them and exit the vehicle unassisted
regardless of the vehicle’s position.
T14.11
Driver’s Equipment Condition
All driving apparel covered by ARTICLE T14 must be in good condition. Specifically, driving
apparel must not have any tears, rips, open seams, areas of significant wear or abrasion or stains
which might compromise fire resistant performance.
T14.12
Fire Resistant Material
For the purpose of this section some, but not all, of the approved fire resistant materials are: Carbon
X, Indura, Nomex, Polybenzimidazole (commonly known as PBI) and Proban.
T14.13
Synthetic Material – Prohibited
T-shirts, socks or other undergarments (not to be confused with FR underwear) made from nylon or
any other synthetic material which will melt when exposed to high heat are prohibited.
T14.14
Camera Mounts
T14.14.1 The mounts for video/photographic cameras must be of a safe and secure design.
T14.14.2 All camera installations must be approved at Technical Inspection.
T14.14.3 Helmet mounted cameras are prohibited.
T14.14.4 The body of a camera or recording unit that weighs more than 0.25 kg (9 oz) must be secured at a
minimum of 2 points on different sides of the camera body, neither of the attachments can be elastic
or plastic. If a tether is used to restrain the camera, the tether length must be limited so that the
camera cannot contact the driver.
ARTICLE T15 OTHER REQUIRED EQUIPMENT
T15.1
Fire Extinguishers
T15.1.1 Each team must have at least two (2) 2.3 kg (5 lb.) dry chemical (Min. 3-A:40-B:C) Fire
extinguishers
T15.1.2 Extinguishers of larger capacity (higher numerical ratings) are acceptable.
T15.1.3 All extinguishers must be equipped with a manufacturer installed pressure/charge gauge.
74
© 2014 SAE International
Rev. 2 - October 15, 2014
T15.2
Special Requirements
Teams must identify any fire hazards specific to their vehicle’s components and if fire
extinguisher/fire extinguisher material other than those required in section T15.1are needed to
suppress such fires, then at least two (2) additional extinguishers/material (at least 5 lb or
equivalent) of the required type must be procured and accompany the car at all times. As
recommendations vary, teams are advised to consult the rules committee before purchasing
expensive extinguishers that may not be necessary.
T15.3
Chemical Spill Absorbent
Teams must have chemical spill absorbent at hand, appropriate to their specific risks. This material
must be presented at technical inspection.
T15.4
Insulated Gloves
Insulated gloves, rated for at least the voltage in the TSV system, with protective over-gloves.
Electrical gloves require testing by a qualified company and must have a test date printed on them
that is within 14 months of the competition.
T15.5
Safety Glasses
Safety glasses must be worn as specified in section D10.7
T15.6
MSDS Sheets
Materials Safety Data Sheets (MSDS) for the accumulator.
T15.7
Additional
Any special safety equipment called for in the MSDS, for example correct gloves recommended for
handling any electrolyte material in the accumulator.
75
© 2014 SAE International
Rev. 2 - October 15, 2014
PART IC - INTERNAL COMBUSTION ENGINE POWERTRAINS
ARTICLE IC1 INTERNAL COMBUSTION ENGINE POWERTRAINS
IC1.1
Engine Limitation
Engines must be Internal Combustion, four-stroke piston engines, with a maximum displacement of
250cc for spark ignition engines and 310cc for diesel engines and be either:
(a) Modified or custom fabricated. (See section IC1.2)
Or
(b) Stock – defined as:
(i)
Any single cylinder engine,
or
(ii) Any twin cylinder engine from a motorcycle approved for licensed use on public roads,
or
(iii) Any commercially available “industrial” IC engine meeting the above displacement
limits.
Note: If you are not sure whether or not your engine qualifies as “stock”, contact the
organizers.
IC1.2
Permitted modifications to a stock engine are:
(a) Modification or removal of the clutch, primary drive and/or transmission.
(b) Changes to fuel mixture, ignition or cam timings.
(c) Replacement of camshaft. (Any lobe profile may be used.)
(d) Replacement or modification of any exhaust system component.
(e) Replacement or modification of any intake system component; i.e., components upstream of
(but NOT including) the cylinder head. The addition of forced induction will move the engine
into the modified category.
(f)
Modifications to the engine casings. (This does not include the cylinders or cylinder head.
(g) Replacement or modification of crankshafts for the purpose of simplifying mechanical
connections. (Stroke must remain stock.)
IC1.3
Engine Inspection
The organizers reserve the right to tear down any number of engines to confirm conformance to the
rules. The initial measurement will be made externally with a measurement accuracy of one (1)
percent. When installed to and coaxially with spark plug hole, the measurement tool has dimensions
of 381 mm (15 inches) long and 30 mm (1.2 inches) diameter. Teams may choose to design in
access space for this tool above each spark plug hole to reduce time should their vehicle be
inspected.
IC1.4
Starter
Each car must be equipped with an on-board starter or equivalent, and be able to move without any
outside assistance at any time during the competition. Specifically, push starts are not permitted.
76
© 2014 SAE International
Rev. 2 - October 15, 2014
A manual starting system operable by the driver while belted in is permissible.
IC1.5
Air Intake System
IC1.5.1
Air Intake System Location
All parts of the engine air and fuel control systems (including the throttle or carburetor, and the
complete air intake system, including the air cleaner and any air boxes) must lie within the surface
defined by the top of the roll bar and the outside edge of the four tires. (See Figure 24)
Figure 24- Surface Envelope
IC1.5.2
Any portion of the air intake system that is less than 350 mm (13.8 inches) above the ground must
be shielded from side or rear impact collisions by structure built to Rule T3.24 or T3.33 as
applicable.
IC1.5.3
Intake Manifold
If an intake manifold is used, it must be securely attached to the engine crankcase, cylinder, or
cylinder head with brackets and mechanical fasteners. This precludes the use of hose clamps, plastic
ties, or safety wires.
Original equipment rubber parts that bolt or clamp to the cylinder head and to the throttle body or
carburetor are acceptable.
Note: These rubber parts are referred to by various names by the engine manufacturers; e.g.,
“insulators” by Honda, “joints” by Yamaha, and “holders” by Kawasaki.
Other than such original equipment parts the use of rubber hose is not considered a structural
attachment. Intake systems with significant mass or cantilever from the cylinder head must be
supported to prevent stress to the intake system.
77
© 2014 SAE International
Rev. 2 - October 15, 2014
Supports to the engine must be rigid.
Supports to the frame or chassis must incorporate some isolation to allow for engine movement and
chassis flex.
IC1.5.4
Air boxes and filters
Large air boxes must be securely mounted to the frame or engine and connections between the air
box and throttle must be flexible. Small air cleaners designed for mounting to the carburetor or
throttle body may be cantilevered from the throttle body.
IC1.6
Accelerator and Accelerator Actuation
IC1.6.1
Carburetor/Throttle Body
All spark ignition engines must be equipped with a carburetor or throttle body. The carburetor or
throttle body may be of any size or design.
IC1.6.2
Accelerator Actuation - General
All systems that transmit the driver’s control of the speed of the vehicle, commonly called
“Accelerator systems”, must be designed and constructed as “fail safe” systems, so that the failure
of any one component, be it mechanical, electrical or electronic, will not result in an uncontrolled
acceleration of the vehicle. This applies to both IC engines and to electric motors that power the
vehicle.
The Accelerator control may be actuated mechanically, electrically or electronically, i.e. electrical
Accelerator control (ETC) or “drive-by-wire” is acceptable.
Any Accelerator pedal must have a positive pedal stop incorporated on the Accelerator pedal to
prevent over stressing the Accelerator cable or any part of the actuation system.
IC1.6.3
Mechanical Accelerator Actuation
If mechanical Accelerator actuation is used, the Accelerator cable or rod must have smooth
operation, and must not have the possibility of binding or sticking.
The Accelerator actuation system must use at least two (2) return springs located at the throttle
body, so that the failure of any component of the Accelerator system will not prevent the
Accelerator returning to the closed position.
Note: Springs in Throttle Position Sensors (TPS) are NOT acceptable as return springs.
Accelerator cables must be at least 50.8 mm (2 inches) from any exhaust system component and out
of the exhaust stream.
Any Accelerator pedal cable must be protected from being bent or kinked by the driver’s foot when
it is operated by the driver or when the driver enters or exits the vehicle.
If the Accelerator system contains any mechanism that could become jammed, for example a gear
mechanism, then this must be covered to prevent ingress of any debris.
The use of a push-pull type Accelerator cable with a Accelerator pedal that is capable of forcing the
Accelerator closed (e.g. toe strap) is recommended.
Electrical actuation of a mechanical throttle is permissible, provided releasing the Accelerator pedal
will override the electrical system and cause the throttle to close.
IC1.6.4
Electrical Accelerator Actuation
When electrical or electronic throttle actuation is used, the throttle actuation system must be of a
fail-safe design to assure that any single failure in the mechanical or electrical components of the
78
© 2014 SAE International
Rev. 2 - October 15, 2014
Accelerator actuation system will result in the engine returning to idle (IC engine) or having zero
torque output (electric motor). See also: EV2.2.
Teams are strongly encouraged to use commercially available electrical Accelerator actuation
systems.
The methodology used to ensure fail-safe operation must be included as a required appendix to the
Design Report. See S4.2.1 A printed copy must be handed to inspectors at the beginning of
Electrical Tech Inspection.
IC1.7
Intake System Restrictor
IC1.7.1
Non-stock engines (See IC1.1) must be fitted with an air inlet restrictor as listed below. All the air
entering the engine must pass through the restrictor which must be located downstream of any
engine throttling device.
IC1.7.2
The restrictor must be circular with a maximum diameter of:
(a) Gasoline fueled cars – 12.9 mm (0.508 inch)
(b) E-85 fueled cars – 12.3 mm (0.483 inch)
(c) Biodiesel fueled cars – no inlet restrictor required
IC1.7.3
The restrictor must be located to facilitate measurement during the inspection process.
IC1.7.4
The circular restricting cross section may NOT be movable or flexible in any way, e.g. the restrictor
may not be part of the movable portion of a barrel throttle body.
IC1.7.5
Any device that has the ability to throttle the engine downstream of the restrictor is prohibited.
IC1.7.6
If more than one engine is used, the intake air for all engines must pass through the one restrictor.
Note: Section IC1.7 applies only to those engines that are not on the approved stock engine list, or
that have been modified beyond the limits specified in IC1.2.
IC1.8
Turbochargers & Superchargers
Turbochargers or superchargers are permitted. The compressor must be located downstream of the
inlet restrictor. The addition of a Turbo or Supercharger will move the engine into the Modified
category.
IC1.9
Fuel Lines
IC1.9.1
Plastic fuel lines between the fuel tank and the engine (supply and return) are prohibited.
IC1.9.2
If rubber fuel line or hose is used, the components over which the hose is clamped must have
annular bulb or barbed fittings to retain the hose. Also, clamps specifically designed for fuel lines
must be used. These clamps have three (3) important features;
(a) A full 360 degree (360°) wrap,
(b) a nut and bolt system for tightening, and
(c) rolled edges to prevent the clamp cutting into the hose.
Worm-gear type hose clamps are not approved for use on any fuel line.
IC1.9.3
Fuel lines must be securely attached to the vehicle and/or engine.
IC1.9.4
All fuel lines must be shielded from possible rotating equipment failure or collision damage.
IC1.10
Fuel Injection System Requirements
IC1.10.1 Fuel Lines – Flexible fuel lines must be either
79
© 2014 SAE International
Rev. 2 - October 15, 2014
(a) metal braided hose with either crimped-on or reusable, threaded fittings, or
(b) reinforced rubber hose with some form of abrasion resistant protection with fuel line clamps
per IC1.9.2.
Note: Hose clamps over metal braided hose will not be accepted.
IC1.10.2 Fuel Rail – The fuel rail must be securely attached to the engine cylinder block, cylinder head, or
intake manifold with brackets and mechanical fasteners. This precludes the use of hose clamps,
plastic ties, or safety wire.
IC1.11
Crankcase / engine lubrication venting
IC1.11.1 Any crankcase or engine lubrication vent lines routed to the intake system must be connected
upstream of the intake system restrictor, if fitted.
IC1.11.2 Crankcase breathers that pass through the oil catch tank(s) to exhaust systems, or vacuum devices
that connect directly to the exhaust system, are prohibited.
ARTICLE IC2 FUEL AND FUEL SYSTEM
IC2.1
Fuel
IC2.1.1
All fuel at the Formula Hybrid Competition will be provided by the organizer.
IC2.1.2
During all performance events the cars must be operated with the fuels provided by the organizer.
IC2.1.3
The fuels provided at the Formula Hybrid Competition are:
(a) Gasoline (Sunoco Optima)
(b) Ethanol (Sunoco E-85R)
(c) Diesel (B100)
Note: More information including the fuel energy equivalencies, and a link for the Sunoco fuel
specifications are given in Appendix A
IC2.1.4
Teams must submit their fuel request to the organizers before the fuel request deadline. Only those
fuels listed in IC2.1.3 will be available.
IC2.2
Fuel Additives - Prohibited
IC2.2.1
Nothing may be added to the provided fuels. This prohibition includes nitrous oxide or any other
oxidizing agent.
IC2.2.2
No agents other than fuel and air may be induced into the combustion chamber. Non-adherence to
this rule will be reason for disqualification.
IC2.2.3
Officials have the right to inspect the oil.
IC2.3
Fuel Temperature Changes - Prohibited
The temperature of fuel introduced into the fuel system may not be changed with the intent to
improve calculated fuel efficiency.
IC2.4
Fuel Tanks
IC2.4.1
The fuel tank is defined as that part of the fuel containment device that is in contact with the fuel. It
may be made of a rigid material or a flexible material.
IC2.4.2
Fuel tanks made of a rigid material cannot be used to carry structural loads, e.g. from roll hoops,
suspension, engine or gearbox mounts, and must be securely attached to the vehicle structure with
80
© 2014 SAE International
Rev. 2 - October 15, 2014
mountings that allow some flexibility such that chassis flex cannot unintentionally load the fuel
tank.
IC2.4.3
Any fuel tank that is made from a flexible material, for example a bladder fuel cell or a bag tank,
must be enclosed within a rigid fuel tank container which is securely attached to the vehicle
structure. Fuel tank containers (containing a bladder fuel cell or bag tank) may be load carrying.
IC2.4.4
Any size fuel tank may be used.
IC2.4.5
The fuel system must have a drain fitting for emptying the fuel tank. The drain must be at the lowest
point of the tank and be accessible from under the vehicle. It must not protrude below the lowest
plane of the vehicle frame, and must have provision for safety wiring.
IC2.5
Fuel System Location Requirements
IC2.5.1
All parts of the fuel storage and supply system must lie within the surface defined by the top of the
roll bar and the outside edge of the four tires. (See Figure 24).
IC2.5.2
All fuel tanks must be shielded from side or rear impact collisions. Any fuel tank which is located
outside the Side Impact Structure required by T3.24 or T3.33 must be shielded by structure built to
T3.24 or T3.33.
IC2.5.3
A firewall must be incorporated to separate the fuel tank from the driver, per T4.5.
IC2.6
Fuel Tank Filler Neck & Sight Tube
IC2.6.1
All fuel tanks must have a filler neck:
(a) With a minimum diameter of 38 mm (1.5 inches)
(b) That is vertical (with a horizontal filler cap) or angled at no more than forty-five degrees (45º)
from the vertical.
IC2.6.2
All filler caps and necks must have provision for a seal to be attached such that the filler cap may
not be removed without the removal of the seal. This should consist of two 3 mm (1/8 inch) holes,
one on the neck and one on the cap. When the fuel cap is secured, these holes should be located
within 6 mm (¼ inch) of each other.
IC2.6.3
Any sight tube must not run below the top surface of the fuel tank.
81
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 25 - Filler Neck
IC2.7
Tank Filling Requirement
IC2.7.1
The tank must be capable of being filled to capacity without manipulating the tank or vehicle in any
way (shaking vehicle, etc.).
IC2.7.2
The fuel system must be designed such that the spillage during refueling cannot contact the driver
position, exhaust system, hot engine parts, or the ignition system.
IC2.7.3
Belly pans must be vented to prevent accumulation of fuel.
IC2.8
Venting Systems
IC2.8.1
The fuel tank and carburetor venting systems must be designed such that fuel cannot spill during
hard cornering or acceleration. This is a concern since motorcycle carburetors normally are not
designed for lateral accelerations.
IC2.8.2
All fuel vent lines must be equipped with a check valve to prevent fuel leakage when the tank is
inverted. All fuel vent lines must exit outside the bodywork.
ARTICLE IC3 EXHAUST SYSTEM AND NOISE CONTROL
IC3.1
Exhaust System General
IC3.1.1
Exhaust Outlet
The exhaust must be routed so that the driver is not subjected to fumes at any speed considering the
draft of the car.
IC3.1.2
The exhaust outlet(s) must not extend more than 45 cm (17.7 inches) behind the centerline of the
rear wheels, and shall be no more than 60 cm (23.6 inches) above the ground.
82
© 2014 SAE International
Rev. 2 - October 15, 2014
IC3.1.3
Any exhaust components (headers, mufflers, etc.) that protrude from the side of the body in front of
the main roll hoop must be shielded to prevent contact by persons approaching the car or a driver
exiting the car.
IC3.1.4
The application of fibrous material, e.g. “header wrap”, to the outside of an exhaust manifold or
exhaust system is prohibited.
IC3.2
Noise Measuring Procedure
IC3.2.1
The sound level will be measured during a static test. Measurements will be made with a free-field
microphone placed free from obstructions at the exhaust outlet level, 0.5 m (19.68 inches) from the
end of the exhaust outlet, at an angle of forty-five degrees (45°) with the outlet in the horizontal
plane. The test will be run with the gearbox in neutral at the engine speed defined below. Where
more than one exhaust outlet is present, the test will be repeated for each exhaust and the highest
reading will be used.
Vehicles that do not have manual throttle control must provide some means for running the engine
at the test RPM.
IC3.2.2
The car must be compliant at all engine speeds up to the test speed defined below.
IC3.2.3
If the exhaust has any form of movable tuning or throttling device or system, it must be compliant
with the device or system in all positions. The position of the device must be visible to the officials
for the noise test and must be manually operable by the officials during the noise test.
IC3.2.4
Test Speeds
The test speed for a given engine will be the engine speed that corresponds to an average piston
speed of 914.4 m/min (3,000 ft/min) for automotive or motorcycle engines, and 731.5 m/min (2,400
ft/min) for Diesels and “Industrial” engines. The calculated speed will be rounded to the nearest 500
rpm. The test speeds for typical engines will be published by the organizers.
IC3.2.5
An “industrial engine” is defined as an engine which, according to the manufacturers’ specifications
and without the required restrictor, is not capable of producing more than 5 hp per 100cc. To have
an engine classified as “an industrial engine”, approval must be obtained from organizers prior to
the Competition.
IC3.2.6
Vehicles not equipped with engine tachometers must provide some external means for measuring
RPM, such as a hand-held meter or lap top computer.
Note: Teams that do not provide the means to measure engine speed will not pass the noise test, will
not receive the sticker and hence will not be eligible to compete in any dynamic event .Engines with
mechanical, closed loop speed control will be tested at their maximum (governed) speed.
IC3.2.7
Engines with mechanical, closed loop speed control will be tested at their maximum (governed)
speed.
IC3.3
Maximum Sound Level
The maximum permitted sound level is 110 dB A, fast weighting.
IC3.4
Noise Level Re-testing
At the option of the officials, noise can be measured at any time during the competition. If a car fails
the noise test, it will be withheld from the competition until it has been modified and re-passes the
noise test.
83
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE IC4 ELECTRICAL SYSTEM AND SHUTDOWN SYSTEM
IC4.1
Master Switches
See: Grounded Low Voltage System Master Switch EV5.2
IC4.2
Shutdown Buttons
The shutdown buttons as defined in EV5.3 must also kill the engine and fuel pumps.
IC4.3
Batteries
See EV3.7.
IC4.4
Brake Over-Travel Switch
The Brake Over-Travel Switch forms part of the shutdown system and as defined in T7.3 must kill
the engine and fuel pumps.
84
© 2014 SAE International
Rev. 2 - October 15, 2014
PART EV - ELECTRICAL POWERTRAINS AND SYSTEMS
ARTICLE EV1 ELECTRIC SYSTEM DEFINITIONS
EV1.1
Basic Definitions
EV1.1.1 The Accumulator is defined as all the batteries or capacitors that store the electrical energy to be
used by the tractive system.
EV1.1.2 Accumulator Segments are sub-divisions of the accumulator and must respect either a maximum
voltage or energy limit. (See EV3.3.3). Splitting the accumulator into segments is intended to
reduce the risks associated with working on the accumulator.
EV1.1.3 The Tractive System of the car is defined as every part that is electrically connected to the motor(s)
and accumulators.
EV1.1.4 The Grounded Low Voltage (GLV) system of the car is defined as every electrical part that is not
part of the tractive system.
EV1.2
Grounded Low Voltage and Tractive System Voltage
EV1.2.1 The maximum permitted operating voltage for Formula Hybrid is 300 V. (See Table 9). The
maximum operating voltage is defined as the maximum measured accumulator voltage during
normal charging conditions.
Note 1: The Tractive System Voltage limit may be exceeded within the motor/controller system as a
result of transient inductive effects, but may not be intentionally increased through the use of
DC/DC converters, transformers, etc.
Note 2: Commercially available motor controllers containing boost converters that have internal
voltages greater than 300 VDC may be used provided the unit is approved in advance by the
electrical rules committee.
EV1.2.2 The GLV system may not have a voltage greater than 30 VDC or 25 VAC6. (See Table 9).
EV1.2.3 The GLV system must be grounded to the chassis. See EV3.7.6
EV1.2.4 The tractive and GLV system must be galvanically isolated from one another.
Note: The border between tractive and GLV systems is the galvanic isolation between both systems.
Therefore, some components, such as the motor controller, may be part of both systems.
EV1.2.5 The tractive system must be completely electrically isolated from the chassis and any other
conductive parts of the car.
EV1.2.6 The tractive system motor(s) must be connected to the accumulator through a motor controller.
Bypassing the control system and connecting the tractive system accumulator directly to the
motor(s) is prohibited.
EV1.2.7 The GLV system must be powered up before it is possible to activate the tractive system. (See
EV4.7). Furthermore, a failure causing the GLV system to shut down must immediately deactivate
the tractive system as well.
6
GLV system voltages up to 60Vdc may be allowed with prior review and approval of the rules committee.
85
© 2014 SAE International
Rev. 2 - October 15, 2014
Formula Hybrid Maximum Voltages
Maximum operating voltage
300 V
Maximum GLV
30 VDC or 25 VAC
Table 9 – Maximum Voltages
EV1.3
Electrical Insulating Materials
EV1.3.1 All Electrical insulating materials used must:
(a) be UL recognized (i.e, have an Underwriters Laboratories (www.UL.com) or equivalent rating
and certification).
(b) be rated for the maximum expected operating temperatures at the location of use or
(c) have a minimum temperature rating of 90C. (Whichever is greater)
Note: Electrical insulating barriers used to meet the requirements of EV4.1.5 for separation of
tractive system and GLV wiring must be rated for 150 ºC.
EV1.3.2 Vinyl electrical insulating tape and rubber-like paints and coatings are not acceptable electrical
insulating materials.
ARTICLE EV2 ELECTRIC POWERTRAIN
EV2.1
Accelerator Pedal
EV2.1.1 The accelerator pedal must be a right-foot-operated foot pedal.
EV2.1.2 The foot pedal must return to its original, rearward position when released. The foot pedal must
have positive stops at both ends of its travel, preventing its sensors from being damaged or
overstressed.
EV2.2
Accelerator Signal Limits Check
EV2.2.1 All analog acceleration control signals (between accelerator pedal and motor controller) must have
error checking which can detect open circuit, short to ground and short to sensor power and will
shut down the torque production in less than one (1) second if a fault is detected.
EV2.2.2 The accelerator signal limit shutoff may be tested during electrical tech inspection by replicating
any of the fault conditions listed in EV2.2.1
ARTICLE EV3 TRACTIVE SYSTEM - ENERGY STORAGE
EV3.1
Allowed Tractive System Accumulators
EV3.1.1 The following accumulators are acceptable; batteries (e.g. lithium-ion batteries, NiMH batteries,
lead acid batteries and many other rechargeable battery chemistries) and capacitors, such as super
caps or ultracaps.
The following accumulators are not permitted; molten salt batteries, thermal batteries, fuel cell,
atomic and flywheel mechanical batteries.
EV3.1.2 Manufacturer’s data sheets showing the rated specification of the accumulator cell(s) which are used
must be provided in the ESF along with their number and configurations.
86
© 2014 SAE International
Rev. 2 - October 15, 2014
EV3.2
Tractive System Accumulator Container – General Requirements
EV3.2.1 All batteries or capacitors which store the tractive system energy must be enclosed in (an)
accumulator container(s)
EV3.2.2 If spare accumulators are to be used then they all must be of the same size, weight and type as those
that are replaced. Spare accumulator packs must be presented at Electrical Tech Inspection.
EV3.2.3 If the accumulator container(s) is not easily accessible during Electrical Tech Inspection, detailed
pictures of the internals taken during assembly must be provided. If the pictures do not adequately
depict the accumulator, it may be necessary to disassemble the accumulator to pass Electrical Tech
Inspection.
EV3.3
Tractive System Accumulator Container - Electrical Configuration
EV3.3.1 If the container is made of electrically conductive material, the poles of the accumulator stack(s)
and/or cells must be electrically insulated from the inside wall of the accumulator container by
insulating material rated for the maximum voltage of the tractive system.
All conductive surfaces on the outside of the container must have a low-resistance connection to the
GLV system ground. All conductive penetrations (mounting hardware, etc.) must be located outside
of the insulation and configured such that there is no possibility that they could penetrate the
insulating barrier.
EV3.3.2 Every accumulator container must contain at least one fuse See EV3.5.
EV3.3.3 All batteries or capacitors that make up the accumulator must be divided into accumulator segments.
A Segment Maintenance Disconnect (SMD) must be installed between each segment, to allow
electrical separation such that the separated segments contain a maximum voltage of less than 120
VDC (fully charged) and a maximum energy as specified in Table 10.
Chemistry
PbAcid
NiMh
LiIon (except LiFePO4)
LiFePO4
Capacitor
Segment
Energy Limit
12MJ
12MJ
5MJ
12MJ
5MJ
Table 10 - AMS Segment Energy Limit
Note: If the high-voltage disconnect (HVD, section EV4.7) is located between segments, it satisfies
the requirement for an SMD between these segments. (See Figure 26)
87
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 26 - Example Accumulator Segmenting
The SMD must be used whenever the accumulator containers are opened for maintenance and
whenever accumulator segments are removed from the container.
EV3.3.4 The SMD may be implemented with a switch or a removable maintenance plug. There must be a
positive means of securing the SMD in the disconnected state; for example, a lockable switch can be
secured with a padlock or simply a clip. A removable plug meets this requirement if the plug is
secured or fully removed such that it cannot accidentally reconnect. SMD methods requiring tools
to isolate the segments will not be accepted. If the SMD is operated with the accumulator container
open, any removable part used with the SMD (e.g., a clip or padlock used to secure the SMD off, or
a plug that is removed) must be non-conductive on surfaces that are not used to make electrical
connections.
EV3.3.5 Contacting / interconnecting the single cells by soldering in the high current path is prohibited.
88
© 2014 SAE International
Rev. 2 - October 15, 2014
Note: Soldering wires to cells for the voltage monitoring input of the AMS is allowed since these
wires are not part of the high current path.
EV3.3.6 Each accumulator container must have a prominent indicator, such as an LED, that is visible
through a closed container and will illuminate whenever a voltage greater than 30 VDC is present at
the vehicle side of the AIRs.
EV3.3.7 The accumulator voltage indicator (see EV3.3.6) must be directly controlled by voltage being
present at the connectors using hard-wired electronics. (No software control is permitted).
Activating the indicator with the control signal which closes the Accumulator Isolation Relays
(AIRs) is not sufficient.
EV3.3.8 The accumulator voltage indicator must always work, e.g. even if the container is removed from the
car.
EV3.3.9 The minimum spacing or creepage distance7 for conductive materials at different voltages in the
Accumulator shall be according to Table 11. This requirement applies to all conductors including
cell-to-cell connections.
Maximum Vehicle
TS Voltage
0-150 VDC
150-300 VDC
300-600 VDC
Spacing
Over Surface
Through Air
6.4 mm (1/4”) 3.2 mm (1/8”)
9.5 mm (3/8”) 6.4 mm (1/4”)
12.7 mm (1/2”) 9.5 mm (3/8”)
Table 11 - Accumulator spacing
EV3.4
Tractive System Accumulator Container - Mechanical Configuration
EV3.4.1 All accumulator containers must be rugged and rigidly mounted to the chassis to prevent the
containers from loosening during the dynamic events or possible accidents.
EV3.4.2 The mounting system for the accumulator container must be designed to withstand forces from a
40g deceleration in the horizontal plane and 20g deceleration in the vertical plane. The
calculations/tests proving this must be part of the SES.
(a) For tube frame cars, each accumulator container must be attached to the Frame by a minimum of
four (4) 8 mm Metric Grade 8.8 (5/16 inch Grade 5) bolts.
(b) For monocoques:
7
(i)
Each accumulator container must be attached to the Frame at a minimum of four (4) points,
each capable of carrying a load in any direction of 400 Newtons x the mass of the
accumulator in kgs, i.e if the accumulator has a mass of 50 kgs, each attachment point must be
able to carry a load of 20kN in any direction.
(ii)
The laminate, mounting plates, backing plates and inserts must have sufficient shear area,
weld area and strength to carry the specified load in any direction. Data obtained from the
laminate perimeter shear strength test (T3.30) should be used to prove adequate shear area is
provided
Creepage distance is the shortest distance measured along the surface of the insulating material between two conductors.
89
© 2014 SAE International
Rev. 2 - October 15, 2014
(iii) Each attachment point requires a minimum of one (1) 8 mm Metric Grade 8.8 (5/16 inch SAE
Grade 5) bolt.
(iv)
Each attachment point requires steel backing plates with a minimum thickness of 2 mm.
Alternate materials may be used for backing plates if equivalency is approved.
(v)
The calculations/tests must be included in the SES.
EV3.4.3 All accumulator containers must lie within the surface envelope as defined by IC1.5.1
EV3.4.4 The accumulator container(s) must be built of mechanically robust material; See EV3.4.1.
EV3.4.5 The container material must be fire resistant according to UL94-V0, FAR25 or equivalent.
EV3.4.6 The cells and/or segments must be appropriately secured against loosening inside the container. All
accumulator segments must be attached to the accumulator container(s) with mechanical fasteners.
The fasteners must comply with ARTICLE T11.
EV3.4.7 The accumulator segments contained within the accumulator must be separated by an electrically
insulating barrier such that the limits of EV3.3.3 are met. For all lithium based cell chemistries,
except those based on LiFePO4, these barriers must also be fire resistant (according to UL94-V0,
FAR25 or equivalent).
EV3.4.8 Holes in the container are only allowed for the wiring-harness, ventilation, cooling or fasteners.
These holes must be sealed according to EV4.5.
EV3.4.9 The container must be completely closed at all times when mounted to the car and also when
dismounted from the car without the need to install extra protective covers. Openings for ventilation
should be of a reasonable size, e.g. completely open side pods containing accumulators are not
allowed.
EV3.4.10 A sticker with an area of at least 750mm² and a red or black lightning bolt on yellow background or
red lightning bolt on white background must be applied on every accumulator container. The sticker
must also contain the text “High Voltage” or something similar if the accumulator voltage is greater
than 30 VDC.
EV3.4.11 Any accumulator that may vent an explosive gas must have a ventilation system or pressure relief
valve to prevent the vented gas from reaching an explosive concentration.
EV3.4.12 Every accumulator container which is completely sealed must have a pressure relief valve to prevent
high-pressure in the container.
EV3.5
Accumulator Isolation Relay(s) (AIR)
EV3.5.1 At least two isolation relays must be installed in every accumulator container.
EV3.5.2 The accumulator isolation relays must open both poles of the accumulator.
EV3.5.3 If these relays are open, no TSV may be present outside of the accumulator container. (Including to
the AMS)
EV3.5.4 The isolation relays must be of a “normally open” type.
EV3.5.5 The fuse protecting the accumulator circuit must have a rating lower than the voltage and current
ratings of the isolation relays.
Note: The AIR contacts must be protected by Pre-Charge and Discharge circuitry, See EV4.9
EV3.5.6 Accumulator isolation relays containing mercury are not permitted.
90
© 2014 SAE International
Rev. 2 - October 15, 2014
EV3.6
Accumulator Management System (AMS)
EV3.6.1 Each accumulator must be monitored by an accumulator management system whenever the tractive
system is active or the accumulator is connected to a charger.
EV3.6.2 The AMS must continuously measure cell voltages in order to keep those voltages inside the
allowed minimum and maximums stated in the cell data sheet. If single cells are directly connected
in parallel, only one voltage measurement is needed. (See Table 12)
Maximum number of cells per
voltage measurement
PbAcid
6
NiMh
6
Lithium based
1
Chemistry
Table 12 - AMS Voltage Monitoring
EV3.6.3 The AMS must continuously measure the temperatures of critical points of the accumulator to keep
the cells below the allowed maximum cell temperature bound stated in the cell data sheet.
EV3.6.4 All voltage sense wires to the AMS must be either protected by fuses as defined in ARTICLE EV6
or must be protected by resistors so that they cannot exceed their current carrying capacity in the
event of a short circuit. Any fuse or resistor must be located as close as possible to the energy
source. If any of these fuses are blown or if the connection to measure the cell voltage is interrupted
in any other way then this must be detected by the AMS and must be reported as a critical voltage
problem. If the AMS monitoring board is directly connected to the cell, it is acceptable to have a
fuse integrated into the monitoring board.
EV3.6.5 Any GLV connection to the AMS must be galvanically isolated from the TSV. This isolation must
be documented in the ESF
EV3.6.6 All connections from external devices such as laptops to a tractive system component must include
galvanic isolation, and include a connection to frame ground. These connections must be
documented in the ESF.
EV3.6.7 The AMS must monitor the temperature of the minimum number of cells in the accumulator as
specified in Table 13 below. The monitored cells must be equally distributed over the accumulator
container(s).
Chemistry
PbAcid
NiMh
LiIon (except LiFePO4)
LiFePO4
Cells monitored
5%
10%
30%
15%
Table 13 – AMS Temperature Monitoring
NOTE: It is acceptable to monitor multiple cells with one sensor if this sensor has direct contact to
all monitored cells.
NOTE: It is strongly recommended to monitor the temperature of all cells.
91
© 2014 SAE International
Rev. 2 - October 15, 2014
EV3.6.8 The AMS must shut down all the electrical systems, open the AIRs and shut down the I.C. drive
system if critical voltage or temperature values are detected. (See Table 17) The tractive system
must remain disabled until manually reset by a person other than the driver. It must not be possible
for the driver to re-activate the tractive system from within the car in case of an AMS fault.
EV3.6.9 Team-Designed Accumulator Management Systems
Teams may design and build their own Accumulator Management Systems. However,
microprocessor-based accumulator management systems are subject to the following restrictions:
(a) The processor must be dedicated to the AMS function only. However it may communicate with
other systems through shared peripherals or other physical links.
(b) The AMS circuit board must include a watchdog timer. It is strongly recommended that teams
include the ability to test the watchdog function in their designs.
EV3.6.10 AMS Test Port.
A break-out test connector shall be provided inside the accumulator enclosure for AMS voltage
testing. This port allows testing of the AMS by substituting a test box voltage for a measured cell
voltage. See Figure 27.
The connector shall be located where it can be readily accessed during technical testing. The test
connector shall be either:
(a) Four 4 mm shrouded banana jacks arranged in a 1" square, meeting the requirements of EV4.4
or
(b) A four conductor Molex Minifit junior 1 x 4 pin housing, PN 39-01-4040 (Figure 28 A) with
PN 39-00-0039 female receptacles which Mates with Molex Minifit Jr housing, PN 39-014043 (Figure 28 B) with PN 39-00-0041 male pins8.
Figure 27 - AMS Test Connector
Notes: The test connector makes three adjacent cell connections and an AMS input available for
testing:
Connections 1 & 3 can be the existing protected AMS inputs.
8
A set of Molex Minifit Jr. connectors will be provided to teams on request. Contact the organizers at [email protected]
92
© 2014 SAE International
Rev. 2 - October 15, 2014
During tech testing, inspectors will connect a test circuit, energize the tractive system, and vary the
cell voltage sense using the potentiometer in the test circuit. Cell voltage will be measured and
compared to ESF values for AMS trip points.
For normal operation, a jumper (Molex plug housing or insulated banana jumper) that connects pins
2 & 4 is used.
Figure 28 - Molex Minifit Connectors
EV3.7
Grounded Low Voltage System
EV3.7.1 All GLV batteries must be attached securely to the frame.
EV3.7.2 Any wet-cell battery located in the driver compartment must be enclosed in a nonconductive
marine-type container or equivalent and include a layer of 1.5mm of aluminum or equivalent
between the container and driver.
EV3.7.3 The hot (ungrounded) terminal must be insulated.
EV3.7.4 Battery packs based on Lithium Chemistry other than LiFePO4 must have over-voltage, undervoltage, short circuit and over-temperature cell protection.
EV3.7.5 A team built Lithium LV battery pack may be used, but details on how the required protection is
achieved must be included as part of the ESF submission.
EV3.7.6 One terminal of the GLV battery or other GLV power source must be connected to the chassis by a
ground wire. The ground wire must be sized adequately for the GLV system fusing. The ground
wire must be robustly secured and protected from mechanical damage. Note that minimizing the
length of the ground wire is also recommended.
EV3.8
Pouch type Lithium Ion cells
Batteries constructed using pouch type lithium ion cells are subject to the following design
constraints:
Note: These rules do not apply to prismatic or cylindrical cells.
EV3.8.1 Stack arrangement
Cells in a stack (a group of pouch cells) must be arranged face-to-face not edge-to-edge.
EV3.8.2 Expansion Limiter
A mechanical restraining system (the expansion limiter) must limit volumetric expansion. The
expansion limiter must:
(a) Be capable of applying ≥10 psi without yielding at temperatures up to 150 C.
93
© 2014 SAE International
Rev. 2 - October 15, 2014
(b) allow the stack to expand by at least 8% and not more than 12% in volume before reaching 10
psi.
(c) use materials that are fire retardant and immune to creep.
(d) not impinge on the cell separator internal to the cell.
Conductive materials must be electrically insulated from cells.
Expansion limiter calculations (simulation results or appropriate mechanical analysis) must be
included in the ESF.
EV3.8.3 Filler
Soft elastic material (filler) is required between cells.
The filler must:
(a) be evenly distributed through the stack, between every cell.
(b) apply pressure evenly to each cell surface.
(c) be fire resistant and non-conductive.
EV3.8.4 Pouch Cell tabs
Pouch cell tabs must be:
(a) Mechanically restrained so they cannot move in relation to the cell due to vibration or physical
handling.
(b) connected above the level of the tab insulator. No metallic parts of battery assembly may
bridge the insulation gap provided by the tab insulator.
(c) insulated such that it is not possible to short circuit adjacent cells by accident.
EV3.8.5 Repeating Frame
Each cell in a stack must be held in position using a repeating frame or equivalent method. A
repeating frame must not:
(a) change the natural shape of the cell.
(b) impinge on the cell separator internal to the cell.
(c) allow the edges of the cell to move in relation to the cell due to vibration or physical handling.
No cell may be in contact with or be likely to contact sharp corners or metal/plastic burrs.
EV3.8.6 General Construction
Each stack must be firmly anchored in the accumulator enclosure. See EV3.4 Construction must be
robust and mechanically sound. There must be no evidence of shavings or filings from battery
manufacture in the stack. Accumulator electrical spacing requirements must be observed, including
paths through tension rods etc.
94
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE EV4 TRACTIVE SYSTEM – GENERAL REQUIREMENTS
Minimum Conductor/Conductor Spacing
Location
Inside Accumulator
Outside Accumulator
GLV/TS
TS/TS
PCB
Table 16
Table 11
Non-PCB
Table 15
Table 11
PCB
Table 16
Not specified
Non-PCB
Table 15
Not specified
Table 14 - Applicability of different spacing rules
EV4.1
Separation of Tractive System and Grounded Low Voltage System
EV4.1.1 The layout of electrical devices designed by the team must be documented accurately in the ESF.
EV4.1.2 There must be no electrical connection between the frame of the vehicle (or any other conductive
surface that might be inadvertently touched by a crew member or spectator), and any part of any
tractive system circuits.
EV4.1.3 Tractive system and GLV circuits must be physically segregated. I.e. they may not run through the
same conduit or connector, except for interlock circuit connections.
EV4.1.4 GLV circuits must not be present in the accumulator container except for required purposes, for
example the AMS and AIR. This must be demonstrated in the ESF submission.
EV4.1.5 Where both tractive system circuits and GLV circuits are present within an enclosure, they must be
(a)
separated by electrical insulating barriers meeting the requirements of EV4.1.6 or
(b)
separated by the spacings shown in Table 15 through air, or over a surface (similar to those
defined in UL1741):
Voltage
Spacing
V < 100 VDC
1 cm (0.4 inch)
100 VDC < V < 200 VDC
2 cm (0.75 inch)
V > 200 VDC
3 cm (1.2 inch)
Table 15 - Enclosure Conductor Spacing
Insulating barriers used to meet the requirements of EV4.1.5
(c)
Must be UL recognized as electrical insulating materials for a temperature of 150 ºC or
higher.
(d)
Must be adequately robust for the application and in no case thinner than 0.25 mm (0.010”).
(e)
Must be in addition to wire insulation.
(f)
Must extend far enough at the edges to block any path between uninsulated GLV and tractivesystem conductors shorter than the distances specified in Table 15.
95
© 2014 SAE International
Rev. 2 - October 15, 2014
EV4.1.6 Spacing must be clearly defined. Components and cables capable of movement must be positively
restrained to maintain spacing.
EV4.1.7 If tractive system circuits and GLV circuits are on the same circuit board they must be on separate,
clearly defined areas of the board. Furthermore, the tractive system and GLV areas must be clearly
marked on the PCB.
Required spacing between GLV and TS circuits is as shown in the Table 16. If a cut or hole in the
board is used to allow the “through air” spacing, the cut must not be plated with metal, and the
distance around the cut must satisfy the “over surface” spacing requirement.
Maximum Vehicle
TS Voltage
0-50 VDC
50-150 VDC
150-300 VDC
300-600 VDC
Spacing
Through Air
(Cut in board)
1.6 mm (1/16”) 1.6 mm (1/16”)
6.4 mm (1/4”) 3.2 mm (1/8”)
9.5 mm (3/8”) 6.4 mm (1/4”)
12.7 mm (1/2”) 9.5 mm (3/8”)
Over Surface
Table 16 - PCB Conductor Spacing
EV4.1.8 Teams must be prepared to demonstrate spacings on team-built equipment. Information on this
must be included in the ESF (EV9.1). Spare boards and photographs must be available for
inspection. Teams should also be prepared to remove boards for direct inspection if asked to do so
during the technical inspection.
EV4.1.9 Plated prototyping boards having plated holes and/or generic conductor patterns may not be used for
applications where both GLV and TS circuits are present on the same board. Bare perforated board
may be used, if the spacing and marking requirements (EV4.1.7 and EV4.1.8) are met, and if the
board is easily removable for inspection.
EV4.2
Positioning of tractive system parts
(See also: Section T4.5.1)
EV4.2.1 All parts belonging to the tractive system including conduit, cables and wiring must be contained
within the Surface Envelope of the vehicle (See Figure 24) such that they are protected against
being damaged in case of a crash or roll-over situation.
EV4.2.2 If tractive system parts are mounted in a position where damage will occur from a side or rear
impact, for example motors at the rear of the car, they must be protected by a structure meeting the
requirements of T3.3
EV4.2.3 Outboard wheel motors are allowed where the motor is outside of the frame but only if an interlock
is added such that the Shutdown Circuit, EV5.1, is opened if the wheel assembly is damaged or
separates from the car.
EV4.2.4 In side or front view no part of the tractive-system can project below the lower surface of the frame
or the monocoque, whichever is applicable.
EV4.2.5 There must be a layer of an electrically insulating material between any tractive terminal or
connection and the firewall or frame if they are within 50 mm (2 inches) of one another.
96
© 2014 SAE International
Rev. 2 - October 15, 2014
NOTE: If the enclosure of the tractive system component is electrically insulating it can be used to
meet this requirement.
EV4.3
Grounding
EV4.3.1 All accessible metal parts of the vehicle, except conductors and components of the GLV system,
must have a resistance below 300 mΩ (measured with a current of 1A) to GLV system ground.
NOTE: Accessible parts include that those that are exposed in the normal driving configuration or
when the vehicle is partially disassembled for maintenance or charging.
EV4.3.2 All accessible parts of the vehicle containing conductive material (e.g. coated metal parts, carbon
fiber parts, etc.) which might contact a damaged wire or electrical part, no matter if tractive system
or GLV, must have a resistance below 5 ohm to GLV system ground.
EV4.3.3 Electrical conductivity of any part may be tested by checking any point which is likely to be
conductive, for example the driver's harness attachment bolts. Where no convenient conductive
point is available then an area of coating may be removed.
NOTE: Carbon fiber parts may need special measures such as using copper mesh or similar
modifications to keep the ground resistance below 5 ohms.
NOTE: Conductors used for grounding shall be stranded and 16 AWG minimum.
EV4.4
Tractive System Measuring Points (TSMP)
EV4.4.1 Two tractive system voltage measuring points must be installed in an easily accessible well marked
location. Access must not require the removal of body panels.
EV4.4.2 The TSMPs must be protected by a non-conductive housing that can be opened without tools.
EV4.4.3 The TSMP must be protected from being touched with the bare hand / fingers, even when the
housing is opened.
EV4.4.4 4 mm safety banana jacks that accept shrouded (sheathed) banana plugs with non-retractable
shrouds must be used for the TSMPs. See Figure 29 for examples of the correct jacks and of jacks
that are not permitted because they do not accept the required plugs (also shown).
EV4.4.5 The TSMPs must be connected to the positive and negative motor controller/inverter supply lines.
EV4.4.6 Each TSMP must be secured with an appropriately rated current limiting device (fuse, resistor, etc.).
EV4.4.7 The TSMPs will be used to check during Electrical Tech Inspection that the tractive system is shut
down properly in the given time; see EV5.1.3. They are also needed to ensure the isolation of the
tractive system of the vehicle for possible rescue operations after an accident or when work on the
vehicle is to be done.
EV4.4.8 Next to the TSMP a GLV system ground measuring point must be installed. This measuring point
must be connected to the GLV system ground.
EV4.4.9 A 4 mm safety banana jack that accepts shrouded (sheathed) banana plugs with non-retractable
shrouds must be used for the GLV ground measuring point. See Figure 29 for examples of the
correct jacks and of jacks that are not permitted because they do not accept the required plugs (also
shown).
97
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 29 - Shrouded 4mm Banana Jack
EV4.5
TSV Insulation, wiring and conduit
EV4.5.1 All parts especially live wires, contacts, etc. of the tractive system need to be isolated by nonconductive material or covers to be protected from being touched. In order to achieve this, it must
not be possible to touch any tractive system connections with a 10 cm long, 0.6 cm diameter
insulated test probe when the tractive system enclosures are in place.
EV4.5.2 Non-conductive covers must prevent inadvertent human contact with any tractive system circuit.
This must include crew members working on or inside the vehicle. Covers must be secure and
adequately rigid. Body panels that must be removed to access other components, etc. are not a
substitute for enclosing tractive system connections.
EV4.5.3 Tractive systems and containers must be protected from moisture in the form of rain or puddles.
EV4.5.4 All controls, indicators and data acquisition connections or similar must be galvanically isolated
from the tractive system.
EV4.5.5 All electrical insulating material must be appropriate for the application in which it is used. See:
EV1.3
EV4.5.6 All wires and terminals and other conductors used in the tractive system must be sized appropriately
for the continuous rating of the fuse which protects them. Wires must be marked with wire gauge,
temperature rating and insulation voltage rating. Alternatively a manufacturers part number printed
on the wire is sufficient if this can be referenced to a manufacturers data sheet.
The minimum acceptable temperature rating for TSV cables is 90°C.
Note: Many high current fuses can allow significant overcurrent conditions which may be adequate
to cover the peak power requirements and allow sizing of fusing and wiring according to continuous
or RMS needs.
EV4.5.7 All tractive system wiring must be done to professional standards with appropriately sized
conductors and terminals and with adequate strain relief and protection from loosening due to
vibration etc. Conductors and terminals cannot be modified from their original size/shape and must
be appropriate for the connection being made.
EV4.5.8 All tractive system wiring that runs outside of electrical enclosures must be either:
(a) Shielded, dual-insulated cable (in accordance with ISO 6722 / ISO 14572 or approved
equivalent) with a minimum cross section of 25 mm2 (0.039 in2) or
98
© 2014 SAE International
Rev. 2 - October 15, 2014
(b) Enclosed in separate orange non-conductive conduit.
EV4.5.9 If conduit is used, it must be non-metallic and UL Listed as "Conduit".
NOTES:
(a) "Sleeving" does not qualify as conduit.
(b) "UL Recognized" is not the same as "UL Listed" and will not be automatically accepted by the
technical inspectors.
(c) UL Listed Conduit of other colors may be painted orange or wrapped with orange tape provided
it is done in a professional manner. I.e. it will not chip or fall off.
(d) Teams must receive rules committee approval before using any non-UL Listed conduit.
EV4.5.10 Cable or conduit exiting or entering a tractive system enclosure must use a liquid-tight fitting
proving strain relief to the cable or conduit such that it will withstand a force of 200N without
straining the cable9.
The fitting must be one of the following:
(i)
A conduit fitting rated for use with the conduit used or
(ii)
A cable gland rated for use with the cable used or
(iii) A connector rated for use with the cable used. The connector must provide termination
of the shield and latch in place securely enough to meet the strain-relief requirements
listed above. Both portions of the connector must meet or exceed IEC standards IP53
(mated) and IP20 (unmated).
(b)
Tractive system wiring outside of the frame must be in conduit, with the exception of
connections to wheel motors. (Shielded, dual insulated cables without conduit are only
permitted inside the frame.)
(c)
Wiring to outboard wheel motors may be in conduit or shielded dual insulated cable, meeting
the specifications of EV4.5.8. In either case, at least one wire of the interlock system must
accompany each conduit or cable.
EV4.5.11 All tractive system connections must be designed so that they use intentional current paths through
conductors such as copper or aluminum and should not rely on steel bolts to be the primary
conductor. The connections must not include compressible material such as plastic in the stack-up.
EV4.5.12 If shielded, dual-insulated cable is used, (per EV4.5.8(a)) the shield musts be terminated and
connected to chassis ground at both ends of the cable.
EV4.5.13 Tractive system wiring must be mechanically shielded against damage by rotating and / or moving
parts.
EV4.6
Tractive System Enclosures
EV4.6.1 Every housing or enclosure containing parts of the tractive system except motor housings must be
labeled with sticker(s) (minimum 4 x 4 cm) with a red or black lightning bolt on yellow background
or red lightning bolt on white background. The sticker must also contain the text “High Voltage” or
something similar if the voltage is more than 30 VDC or 25 VAC.
EV4.6.2 If the housing material is electrically conductive, it must have a minimum-resistance connection to
GLV system ground; see EV4.3.
EV4.6.3 If external, un-insulated heat sinks are used, they must be properly grounded to the GLV system
ground; see EV4.3.
9
This will be tested during the electrical tech inspection by pulling on the conduit using a spring scale.
99
© 2014 SAE International
Rev. 2 - October 15, 2014
EV4.7
High Voltage Disconnect (HVD)
EV4.7.1 It must be possible to positively break the current path of the tractive system accumulator quickly by
turning off a disconnect switch or removing an accessible element, fuse or connector.
EV4.7.2 It must be possible to disconnect the HVD within 10 seconds in ready-to-race condition.
Ready-to-race means that the car is fully assembled, including having all body panels in position),
with a driver seated in the vehicle and without the car jacked up.
EV4.7.3 The team must demonstrate this during Electrical Tech Inspection. Being able to quickly disconnect
the accumulator(s) from the rest of the tractive system by its connector(s) will satisfy this rule.
EV4.7.4 The disconnect must be clearly marked with "HVD".
EV4.7.5 An interlock must open the shutdown circuit when the HVD is removed.
EV4.7.6 There must be a positive means of securing the HVD in the disconnected state; for example, a
lockable switch can be secured with a padlock or simply a clip. A removable plug meets this
requirement if the plug is secured or fully removed such that it cannot accidentally reconnect.
Teams must establish a formal lockout/tagout procedure10 that is documented in the ESF, and that
all team members know and follow.
EV4.7.7 The recommended electrical location for the HVD is near the middle of the accumulator string. In
this case, it can serve as one of the SMDs (EV3.3.3 and Figure 26)
EV4.7.8 The HVD must be operable without the use of tools.
EV4.8
Activating the Tractive System
EV4.8.1 The driver must be able to re-activate or reset the tractive system from within the cockpit without
the assistance of any other person except for situations in which the AMS or IMD have shut down
the tractive system; see EV5.1.5.
EV4.8.2 Resetting or re-activating the tractive system by operating controls which cannot be reached by the
driver is considered to be working on the car.
EV4.8.3 At least one action in addition to enabling the shutdown circuits is required to set the car to readyto-drive mode. (The car is ready to drive as soon as the motor(s) will respond to the input of the
torque control sensor / acceleration pedal.)
For example, the additional action could be pressing a dedicated “start” button. However this must
be configured such that it cannot inadvertently be left in the “on” position after system shutdown.
Note: This action may also be used to trigger the required “Ready to drive” sound. (See EV4.11)
EV4.9
Pre-Charge and Discharge Circuits
EV4.9.1 The AIR contacts must be protected by a circuit that is able to pre-charge the intermediate circuit to
at least 90% of the rated accumulator voltage before closing the second AIR.. This circuit must be
disabled by a de-activated shutdown circuit; see EV5.1. Therefore, the pre-charge circuit must not
be able to pre-charge the system if the shutdown circuit is open.
EV4.9.2 It is allowed to pre-charge the intermediate circuit for a conservatively calculated time before
closing the second AIR. A feedback via monitoring the intermediate circuit voltage is not required.
EV4.9.3 If a discharge circuit is needed to meet the requirements of EV5.1.3, it must be designed to handle
the maximum discharge current for at least 15 seconds. The calculation proving this must be part of
the ESF.
10
Teams should base their procedures on the OSHA Lockout/Tagout fact sheet where possible:
https://www.osha.gov/OshDoc/data_General_Facts/factsheet-lockout-tagout.pdf
100
© 2014 SAE International
Rev. 2 - October 15, 2014
EV4.9.4 The discharge circuit must be wired in a way that it is always active whenever the shutdown circuit
is open. Furthermore, the discharge circuit must be fail-safe.
EV4.9.5 The pre-charge circuit must operate regardless of the sequence of operations used to energize the
vehicle, including, for example, restarting after being automatically shut down by a safety circuit.
EV4.9.6 All components and insulating materials used in and near the pre-charge circuits must be rated for
the maximum expected operating temperature (see also EV1.3.1(b)). For always-on discharge
circuits and other circuits that dissipate significant power for extended time periods, measurements
of the maximum operating temperature of the power dissipating components (e.g., resistors) must be
included in the ESF. If the resistor operating temperature exceeds the rating of nearby insulating or
structural materials, their temperatures must also be measured.
EV4.10 Tractive-system-active Light (TSAL)
EV4.10.1 The car must be equipped with a TSAL mounted under the highest point of the main roll hoop
which must be lit and clearly visible any time the AIR coils are energized.
EV4.10.2 The TSAL must be red or amber.
EV4.10.3 The TSAL must flash continuously with a frequency between 2 Hz and 5 Hz.
EV4.10.4 It must not be possible for the driver's helmet to contact the TSAL.
EV4.10.5 The TSAL must be clearly visible from every horizontal direction, (except for the small angles
which are covered by the main roll hoop) even in very bright sunlight.
EV4.10.6 The TSAL must be visible from a person standing up to 3m away from the TSAL itself. The
person's minimum eye height is 1.6m.
NOTE: If any official e.g. track marshal, scrutineer, etc. considers the TSAL to not be easily visible
during track operations the team may not be allowed to compete in any dynamic event before the
problem is solved.
EV4.10.7 It is prohibited to mount other lights in proximity to the TSAL.
EV4.11 Ready-To-Drive-Sound
EV4.11.1 The car must make a characteristic sound, for a minimum of 1 second and a maximum of 3 seconds,
when it is ready to drive. (See EV4.8.3)
(The car is ready to drive as soon as the motor(s) will respond to the input of the torque control
sensor / accelerator pedal.)
EV4.11.2 The emitting device must produce a tone of approximately 2500 to 3500 Hz with a minimum
loudness of 68 dB(A) at 2 ft. One device that meets this requirement is the Mallory Sonalert
SC648AJR11.
The emitting device must be located and oriented so as to be easily audible from in front of the
vehicle in noisy environments.
EV4.12 Tractive System Voltage Present (TSVP) indicators
There must be two TSVP lamps. One mounted on each side of the roll bar in the vicinity of the sidemounted shutdown buttons (EV5.3.3) that can easily be seen from the sides of the vehicle.
EV4.12.1 They must be red, complying with DOT FMVSS 108 for trailer clearance lamps12. See Figure 30
EV4.12.2 They must be lit and clearly visible any time the voltage outside the accumulator containers exceeds
30 VDC or 25 VAC RMS.
11
12
http://www.mallory-sonalert.com/specifications/SC648AJR.PDF
http://www.superbrightleds.com - Part Number M9-x4 or equivalent
101
© 2014 SAE International
Rev. 2 - October 15, 2014
EV4.12.3 The TSVP system must be powered entirely by the tractive system and must be directly controlled
by voltage being present at the output of the accumulator (no software control is permitted). TS
wiring and/or voltages must not be present at the lamps themselves.
Note: This requirement may be met by locating an isolated dc-dc converter inside a TS enclosure,
and connecting the output of the dc-dc converter to the lamps. Although the wiring from the dc-dc
converter to the TSVP lamps must not be connected to the main GLV system, it must be groundreferenced by connecting one side of it to the frame or GLV ground in order to comply with
EV1.1.4 and EV1.2.3.
Figure 30 - TSVP Lamp
ARTICLE EV5 SHUTDOWN CIRCUIT AND SYSTEMS
EV5.1
Shutdown Circuit
EV5.1.1 The shutdown circuit must directly carry the current driving the accumulator isolation relays (AIRs).
EV5.1.2 The shutdown circuit consists of at least 2 master switches, 3 shut-down buttons, the brake-overtravel-switch, the insulation monitoring device (IMD), all required interlocks and the accumulator
management system (AMS).
EV5.1.3 If the shutdown circuit is opened/interrupted the tractive system must be shut down by opening all
accumulator isolation relay(s). The voltage in the tractive system must drop to under 30 VDC or 25
VAC RMS in less than five seconds after opening the shutdown circuit.
EV5.1.4 An example schematic of the required shutdown circuit, excluding possibly needed interlock
circuitry, is shown in Figure 33.
EV5.1.5 It must not be possible for the driver to re-activate the tractive system from within the car in case of
an AMS or IMD fault. Remote reset, for example via WLAN or use of the three shutdown buttons
or TSMS to reset the AMS or IMD is not permitted.
Note: Applying an IMD test resistor between tractive system positive and GLV system ground must
deactivate the system. Disconnecting the test resistor must not re-activate the system. The tractive
system must remain inactive until it is manually reset.
EV5.1.6 If the tractive system is de-activated while driving, the motor(s) must spin free, e.g. no braking
torque may be derived from the motor(s).
EV5.1.7 The recommended sequence of operation of the shutdown circuit and related systems is shown in
the form of a state diagram in Figure 31.
102
© 2014 SAE International
Rev. 2 - October 15, 2014
Teams are required to either:
(a) Demonstrate that their vehicle operates according to this state diagram, or,
(b) Obtain approval for an alternative state diagram by submitting an electrical rules query on or
before the ESF submission deadline, and demonstrate that the vehicle operates according to the
approved alternative state diagram.
EV5.1.8 If the shutdown circuit operates differently from the standard or approved alternative state diagram
during inspection, the car will be considered to have failed inspection, regardless of whether the
way it operates meets other rules requirements.
Figure 31 - Example Shutdown State Diagram
EV5.2
Master Switches
EV5.2.1 Each vehicle must have two Master Switches:
(a) Grounded Low Voltage Master Switch (GLVMS)
(b) Tractive System Master Switch (TSMS).
EV5.2.2 The GLVMS must:
(a) Disable power to ALL electrical circuits, including the alternator, lights, fuel pump(s), ignition
and electrical controls.
(b) All battery current must flow through this switch.
103
© 2014 SAE International
Rev. 2 - October 15, 2014
(c) Be of a rotary type and must be direct acting, i.e. it cannot act through a relay.
EV5.2.3 The GLVMS must be located on the right side of the vehicle, in proximity to the Main Hoop, at the
driver’s shoulder height and be easily actuated from outside the car.
Figure 32 - Typical Master Switch
EV5.2.4 The TSMS must be located next to the GLVMS and must open the shutdown circuit. The TSMS
must be direct acting, i.e. it cannot act through a relay or logic.
EV5.2.5 Both master switches must be of the rotary type, with a red, removable key, similar to the one
shown in the explanatory shutdown circuit and in Figure 32.
EV5.2.6 The master switches are not allowed to be easily removable, e.g. mounted onto removable body
work.
EV5.2.7 The function of both switches must be clearly marked with “GLV” and “TSV”. A sticker with a red
or black lightning bolt on a yellow background or red lightning bolt on a white background must
additionally mark the Tractive System Master Switch.
EV5.2.8 The “ON” position of both switches must be parallel to the fore-aft axis of the vehicle
104
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 33 – Example Master Switch and Shutdown Circuit Configuration
EV5.3
Shutdown Buttons
EV5.3.1 A system of three shut-down buttons (“Big Red Buttons” or BRBs) must be installed on the vehicle.
EV5.3.2 Each shut-down button must be a push-pull or push-rotate switch where pushing the button opens
the shutdown circuit. The shut-down buttons must not act through logic, e.g. a micro-controller.
EV5.3.3 Pressing any of the shut-down buttons must separate the tractive system from the accumulator by
opening the shutdown circuit, and must also kill the engine and fuel pumps; see EV5.1.
105
© 2014 SAE International
Rev. 2 - October 15, 2014
EV5.3.4 One button must be located on each side of the vehicle behind the driver’s compartment at
approximately the level of the driver’s head. The minimum allowed diameter of the shutdown
buttons on both sides of the car is 40 mm.
EV5.3.5 In addition to the requirements in EV5.3.3, the side-mounted shutdown buttons must also shut down
all electrical systems. (See Table 17)
Note: Electronic systems may have local energy storage sufficient to allow an orderly shutdown of
operations upon the loss of GLV, but must be prevented from feeding power back into the GLV.
EV5.3.6 One shutdown button is mounted in the cockpit and must be easily accessible by the driver in any
steering wheel position. The minimum allowed diameter of the shutdown button in the cockpit is 24
mm.
The cockpit mounted button must comply with EV5.3.3, but is not required to de-energize control,
instrumentation or telemetry. (See Table 17)
Table 17 - Shutdown Priority Table
EV5.3.7 If the shutdown circuit is opened by the cockpit-mounted shutdown button, it must be driver
resettable. For example: If the driver disables the system by pressing the cockpit-mounted shutdown
button, the driver must then be able to restore system operation by pulling the button back out.
Note: There must be one additional action by the driver after pulling the button back out to
reactivate the motor controller and make the vehicle ready-to-drive, per EV4.8.3.
EV5.3.8 The shutdown buttons are not allowed to be easily removable, e.g. they must not be mounted onto
removable body work.
EV5.4
Brake Over-Travel Switch
EV5.4.1 The brake over-travel switch, as defined in T7.3, must shut down:
(a) The tractive system by opening the shutdown circuit (see EV5.1) and
(b) the engine and fuel pumps, as illustrated in Table 17.
EV5.4.2 The Brake over-travel switch may not be driver resettable. See T7.3.2.
EV5.5
Insulation Monitoring Device (IMD)
EV5.5.1 Every car must have an insulation monitoring device (IMD) installed in the tractive system.
106
© 2014 SAE International
Rev. 2 - October 15, 2014
EV5.5.2 The IMD must be a Bender A-ISOMETER ® iso-F1 IR155-3203 or IR155-3204 or equivalent IMD
approved for automotive use. Equivalency may be approved by the rules committee based on the
following criteria: robustness to vibration, operating temperature range, availability of a direct
output, a self-test facility and must not be powered by the system which is monitored.
EV5.5.3 The response value of the IMD needs to be set to 500 ohm / volt, related to the maximum tractive
system operation voltage.
EV5.5.4 In case of an insulation failure or an IMD failure, the IMD must shut down all the electrical systems,
open the AIRs and shut down the I.C. drive system. (See Table 17) This must be done without the
influence of any logic (e.g., a micro-controller).
EV5.5.5 The tractive system must remain disabled until manually reset by a person other than the driver. It
must not be possible for the driver to re-activate the tractive system from within the car in case of an
IMD-related fault. (See Appendix H – Example Relay Latch Circuits.)
Note: The electrical inspectors may test the IMD by applying a test resistor between tractive system
positive (or negative) and GLV system ground. This must deactivate the system. Disconnecting the
test resistor must not re-activate the system.
EV5.5.6 The status of the IMD must be shown to the driver by a red indicator light in the cockpit that is
easily visible even in bright sunlight. This indicator must light up if the IMD detects an insulation
failure or if the IMD detects a failure in its own operation e.g. when it loses reference ground.
EV5.5.7 The IMD indicator light must be clearly marked with the lettering “IMD” or “GFD” (Ground Fault
Detector).
EV5.5.8 The IMD ground connection must be wired according to the manufacturer's instructions so that the
reference ground detector is functional.
ARTICLE EV6 FUSING
EV6.1
Fusing
EV6.1.1 All electrical systems (including tractive system, grounded low voltage system and charging
system) must be appropriately fused.
Note: For further guidance of fusing, see the Fusing Tutorial on the Formula Hybrid Web site.
EV6.1.2 The continuous current rating of a fuse must not be greater than the continuous current rating of any
electrical component, for example wire, busbar, battery cell or other conductor that it protects. See
Appendix E for ampacity rating of copper wires.
EV6.1.3 All fuses and fuse holders must be rated for the highest voltage in the systems they protect. Fuses
used for DC must be rated for DC, and must carry a DC rating equal to or greater than the system
voltage of the system in which they are used.
EV6.1.4 All fuses must have an interrupt current rating which is higher than the theoretical short circuit
current of the system that it protects.
EV6.1.5 The fuse protecting a circuit or must be physically located at the end of the wiring closest to an
uncontrolled energy source (e.g., a battery).
Note: For this rule, a battery is considered an energy source even for wiring intended to charge the
battery, because current could flow in the opposite direction in a fault scenario.
EV6.1.6 Circuits with branches using smaller wire than the main circuit require fuses located at the
branching point, if the branch wire is too small to be protected by the main fuse for the circuit.
107
© 2014 SAE International
Rev. 2 - October 15, 2014
EV6.1.7
If more than one battery cell or capacitor is used to form a set of single cells in parallel such that
groups of parallel cells are then combined in series, then either each cell must be appropriately fused
or the cell manufacturer must certify that it is acceptable to use this number of single cells in
parallel. Any certification must be included in the ESF.
EV6.1.8 If multiple parallel strings of batteries or capacitors are used then each string must be individually
fused. If individual fuses are used this must provide a total fusing equal to the number of fuses
multiplied by the fuses rating. Any conductors, for example wires, bus bars, cells etc. conducting
the entire pack current must be appropriately sized to this total fusing or an additional fuse must be
used to protect the conductors.
EV6.1.9 Battery packs with low or non-voltage rated fusible links for cell connections may be used provided
that:
(a) A fuse rated at a current three times lower than the sum of the parallel fusible links and
complying with EV6.1 is connected in series.
(b) The accumulator monitoring system can detect an open fusible link, and will shut down the
electrical system by opening the AIRs if a fault is detected.
(c) Fusible link current rating is specified in manufacturer’s data or suitable test data is provided.
EV6.1.10 Cells with internal over-current protection may be used without external fusing or fusible-links if
suitably rated.
Note: Most cell internal over-current protection devices are low or non-voltage rated and conditions
of EV6.1.9 will apply.
EV6.1.11 The ESF must include all details of fuse and fusible link and internal over current protection
including documentation from manufacturer for the particular series and parallel configuration, and
string voltage.
ARTICLE EV7 ELECTRICAL SYSTEM TESTS
Note: The following three tests must be done in order, and each test passed before the next can be
performed. i.e. (IMDT) then (IMT) then the rain test.
EV7.1
Insulation Monitoring Device Test (IMDT)
EV7.1.1 The insulation monitoring device will be tested during Electrical Tech Inspection. This is done by
connecting a resistor between the TSMP (see EV4.4) and several electrically conductive vehicle
parts while the tractive system is active, as shown in the example below.
EV7.1.2 The test is passed if the IMD shuts down the tractive system within 30 seconds at a fault resistance
of 250 ohm / volt (50% below the response value).
EV7.1.3 The IMDT may be repeated at any time during the event. After the car passes the test for the first
time, critical parts of the tractive system will be sealed. The vehicle is not allowed to take part in
any dynamic event if any of the seals are broken until the IMDT is successfully passed again.
108
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 34 – Insulation Monitoring Device Test
EV7.2
Insulation Measurement Test (IMT)
EV7.2.1 The insulation resistance between the tractive system and control system ground will be measured
during Electrical Tech Inspection. The available measurement voltages are 250 V and 500 V. All
cars with a maximum nominal operation voltage below 300 V will be measured with the next
available voltage level. For example, a 175 V system will be measured with 250 V; a 300 V system
will be measured with 500 V etc.
EV7.2.2 To pass the IMT the measured insulation resistance must be at least 500 ohm/volt related to the
maximum nominal tractive system operation voltage.
EV7.3
Rain test
EV7.3.1 Upon passing the rain test a vehicle will receive a “Rain Certified” sticker and may be operated in
damp or wet conditions. See: ARTICLE D3
If the vehicle does not pass the rain test, or if the team chooses to forego the rain test, then the
vehicle is not rain certified and will not be allowed to operate in damp or wet conditions.
EV7.3.2 During the rain test the tractive system must be active and none of the driven wheels may touch the
ground. It is not allowed to have a driver seated in the car during the rain test.
EV7.3.3 Water will then be sprayed at the car from any possible direction for 120 seconds. The water spray
will be rain like. Therefore there will be no direct high-pressure water jet shot at the car.
EV7.3.4 The test is passed if the insulation monitoring device does not react while water is sprayed at the car
and 120 seconds after the water spray has stopped. Therefore the total time of the rain test is 240
seconds, 120 seconds with water-spray and 120 seconds without.
EV7.3.5 Teams must make sure that water cannot aggregate anywhere in the chassis.
ARTICLE EV8 HIGH VOLTAGE PROCEDURES & TOOLS
EV8.1
Working on Tractive System Accumulator Containers
EV8.1.1 If the organizers have provided a “Designated Charging Area”, then opening of or working on
accumulator containers is only allowed in that charging area, see EV8.2, and during Electrical Tech
Inspection.
EV8.1.2 Whenever the accumulator containers are opened the accumulator segments must be separated by
using the maintenance plugs; see EV3.3.3.
109
© 2014 SAE International
Rev. 2 - October 15, 2014
EV8.1.3 Whenever the accumulator or tractive system is being worked on, only appropriate insulated tools
may be used.
EV8.1.4 Whenever the accumulator or tractive system is open or being worked on, a “Danger High Voltage”
sign (or other warning device provided by the organizers) must be displayed.
Note: Be sure to remove the warning sign or indicator once the hazards are no longer present.
EV8.2
Charging
EV8.2.1 If the organizers have provided a “Designated Charging Area”, then charging tractive system
accumulators is only allowed inside this area.
EV8.2.2 Accumulators may be charged inside the car.
EV8.2.3 It is also possible to charge the accumulators outside the car with a removable accumulator
container.
EV8.2.4 The accumulator containers or the car itself, depending on whether the accumulators are charged
externally or internally, must have a label with the following data during charging: Team name and
Safety Responsible phone number(s).
EV8.2.5 Only chargers presented and sealed at Electrical Tech Inspection are allowed. All connections of the
charger(s) must be isolated and covered. No open connections are allowed.
EV8.2.6 No work is allowed on any of the car’s systems during charging if the accumulators are charging
inside of or connected to the car.
EV8.2.7 No grinding, drilling, or any other activity that could produce either sparks or conductive debris. is
allowed in the charging area.
EV8.2.8 At least one team member who has knowledge of the charging process must stay with the
accumulator(s) / car during charging.
EV8.2.9 Moving accumulator cells and/or stack(s) around at the event site is only allowed inside a
completely closed accumulator container.
EV8.2.10 High Voltage wiring in an off board charger does not require conduit; however it must be a UL
listed flexible cable that complies with NEC Article 400; double insulated.
EV8.2.11 All chargers must be UL (Underwriters Laboratories) listed. Any waivers of this requirement
require approval in advance, based on documentation of the safe design and construction of the
system, including galvanic isolation between the input and output of the charger. Waivers for
chargers must be submitted at least 30 days prior to the start of the competition.
EV8.2.12 The vehicle charging connection must be appropriately fused for the rating of its connector and
cabling in accordance with EV6.1.1.
EV8.2.13 The charging port shall only be energized when the tractive system is energized and the TSAL is
flashing.
There shall be no voltage present on the charging port when the tractive system is de-energized.
The external charging system shall be disconnected if there is an AMS or IMD fault, or if one of the
shutdown buttons (See EV5.3) is pressed.
EV8.3
Accumulator Container Hand Cart
EV8.3.1 In case removable accumulator containers are used in order to accommodate charging, a hand cart to
transport the accumulators must be presented at Electrical Tech Inspection.
EV8.3.2 The hand cart must have a brake such that it can only be released using a dead man's switch, i.e. the
brake is always on except when someone releases it by pushing a handle for example.
110
© 2014 SAE International
Rev. 2 - October 15, 2014
EV8.3.3 The brake must be capable to stop the fully loaded accumulator container hand cart.
EV8.3.4 The hand cart must be able to carry the load of the accumulator container(s).
EV8.3.5 The hand cart(s) must be used whenever the accumulator container(s) are transported on the event
site.
EV8.3.6 Each team must present the following basic set of tools in good condition during technical
inspection: (See also Appendix F)
(a) Insulated screw drivers
(b) Multimeter with shrouded banana connectors and protected probe tips
(c) Insulated wrenches, if screwed or bolted connections are used in the tractive system
(d) Face shield which meets ANSI Z87.1-2003
(e) HV insulating gloves which are within 14 Months of the test date and protective outer glove
(f)
2 HV insulating blankets of sufficient size to cover the vehicles accumulator(s)
(g) Safety glasses with side shields (ANSI Z87.1-2003 compliant) for all team members.
Note: All electrical safety items must be rated for at least the maximum tractive system voltage.
ARTICLE EV9 ELECTRICAL SYSTEM FORM AND FMEA
EV9.1
Electrical System Form (ESF)
EV9.1.1 All teams must submit clearly structured documentation, prior to the posted deadline, of their entire
electrical system (including control and tractive system) called the Electrical System Form (ESF).
EV9.1.2 The ESF must illustrate the interconnection of all electric components including the voltage level,
the topology, the wiring in the car and the construction and build of the accumulator(s).
EV9.1.3 Teams must present data pages with rated specifications for all tractive system parts used and show
that none of these ratings are exceeded (including wiring components). This includes stress caused
by the environment e.g. high temperatures, vibration, etc.
EV9.1.4 A template including the required structure for the ESF will be made available online.
EV9.1.5 The ESF must be submitted as an Adobe PDF file.
EV9.1.6 Data pages and large schematics should be put in an appendix.
EV9.2
Failure Modes and Effects Analysis (FMEA)
EV9.2.1 Teams must submit a complete failure modes and effects analysis (FMEA) of the tractive system
prior to the event.
EV9.2.2 A template including required failures to be described will be made available online.
Note: Do not change the format of the template. Pictures, schematics and data sheets to be
referenced in the FMEA must be included in the ESF.
111
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE EV10 ACRONYMS
AC
Alternating Current
AIR
Accumulator Isolation Relay
AMS
Accumulator Management System
ANSI
American National Standards Institute
BRB
Big Red Buttons (Emergency shutdown switches)
DC
Direct Current
ESF
Electrical System Form
EV
Electrical Vehicle
FMEA
Failure Modes and Effects Analysis
GLV
Grounded Low Voltage
GLVMS
Grounded Low Voltage Master Switch
HVD
High Voltage Disconnect
IMD
Insulation Monitoring Device
IMDT
Insulation Monitoring Device Test
IMT
Insulation Measurement Test
LV
Low Voltage
NiMH
Nickel Metal Hydride
PCB
Printed Circuit Board
RMS
Root Mean Squared
TSAL
Tractive System Active Light
TSMP
Tractive System Measuring Point
TSMS
Tractive System Master Switch
TSV
Tractive System Voltage (Formerly “HV”)
TSVP
Tractive Voltage Present
UL
Underwriters Laboratory
112
© 2014 SAE International
Rev. 2 - October 15, 2014
PART S - STATIC EVENTS
ARTICLE S1
STATIC EVENTS AND MAXIMUM SCORES
Technical Inspection
Presentation
Design
Total
0 points
100 points
200 points
300 points
Table 18 – Static Event Maximum Scores
ARTICLE S2
TECHNICAL INSPECTION
S2.1
Objective
S2.1.1
The objective of technical inspection is to determine if the vehicle meets the FH rules requirements
and restrictions and if, considered as a whole, it satisfies the intent of the Rules.
S2.1.2
For purposes of interpretation and inspection the violation of the intent of a rule is considered a
violation of the rule itself.
S2.1.3
Technical inspection is a non-scored activity.
S2.2
Inspection & Testing Requirement
S2.2.1
Each vehicle must pass all parts of technical inspection and testing, and bear the inspection stickers,
before it is permitted to participate in any dynamic event or to run on the practice track. The exact
procedures and instruments employed for inspection and testing are entirely at the discretion of the
Chief Technical Inspector.
S2.2.2
Technical inspection will examine all items included on the Inspection Form found on the Formula
Hybrid website, all the items on the Required Equipment list (Appendix F) plus any other items the
inspectors may wish to examine to ensure conformance with the Rules.
S2.2.3
All items on the Inspection Form must be clearly visible to the technical inspectors.
S2.2.4
Visible access can be provided by removing body panels or by providing removable access panels.
S2.2.5
Once a vehicle has passed inspection, except as specifically allowed under T1.2 Modification and
Repairs, it must remain in the “As-approved” condition throughout the competition and must not be
modified.
S2.2.6
Decisions of the inspectors and the Chief Scrutineer concerning vehicle compliance are final and are
not permitted to be appealed.
S2.2.7
Technical inspection is conducted only to determine if the vehicle complies with the requirements
and restrictions of the Formula Hybrid rules.
S2.2.8
Technical approval is valid only for the duration of the specific Formula Hybrid competition during
which the inspection is conducted.
S2.3
Pre-Competition Electrical Inspection
Vehicles will be inspected at the team’s home institution three (3) weeks before the beginning of the
competition.
113
© 2014 SAE International
Rev. 2 - October 15, 2014
This inspection will be conducted by volunteer inspectors from the IEEE Power Electronics Society
(PELS) or by other qualified professionals. Teams will be contacted by the organizers to coordinate
the inspections.
The purpose of this inspection is to alert teams to possible rules infractions or other safety concerns
while there is still time to correct the problems.
Inspection stickers are not awarded and the results of the on-site inspection are not binding upon the
organizers.
S2.4
Inspection Condition
Vehicles must be presented for technical inspection in finished condition, i.e. fully assembled,
complete and ready-to-run. Technical inspectors will not inspect any vehicle presented for
inspection in an unfinished state.
Note: Cars may be presented for technical inspection even if final tuning and set-up has not been
finished.
S2.5
Inspection Process
Vehicle inspection will consist of five separate parts as follows:
(a) Part 1: Preliminary Electrical Inspection
Vehicles must pass a preliminary electrical safety inspection before they will be permitted to
proceed to Mechanical Scrutineering. A sticker will be affixed to the vehicle upon passing the
Preliminary Electrical Inspection.
(b) Part 2: Scrutineering - Mechanical
Each vehicle will be inspected to determine if it complies with the mechanical and structural
requirements of the rules. This inspection will include examination of the driver’s equipment
(ARTICLE T5) a test of the emergency shutdown response time (Rule T4.9) and a test of the
driver egress time (Rule T4.8).
The vehicle will be weighed, and the weight placed on a sticker affixed to the vehicle for
reference during the Design event (3).
(c) Part 3: Scrutineering – Electrical
Each vehicle will be inspected for compliance with the electrical portions of the rules.
Note: This is an extensive and detailed inspection. Teams that arrive well-prepared can reduce
the time spent in electrical inspection considerably.
The electrical inspection will include all the tests listed in ARTICLE EV7;
Note: In addition to the electrical rules contained in this document, the electrical inspectors will
use SAE Standard J1673 “High Voltage Automotive Wiring Assembly Design” as the definitive
reference for sound wiring practices.
Note: Parts 1, 2 and 3 must be passed before a vehicle may apply for Part 4 or Part 5 inspection.
(d) Part 4: Tilt Table Tests
Each vehicle will be tested to insure it satisfies both the 45 degree (45°) fuel and fluid tilt
requirement (Rule T8.5.1) and the 60 degree (60°) stability requirement (Rule T6.7).
(e) Part 5: Noise, Master Switch, and Brake Tests.
Noise will be tested by the specified method (Rule IC3.2). If the vehicle passes the noise test
then its master switches (ARTICLE IC4 and ARTICLE EV5) will be tested.
114
© 2014 SAE International
Rev. 2 - October 15, 2014
Once the vehicle has passed the noise, master switch tests and then its brakes will be tested by
the specified method (see Rule T7.2).
S2.6
Correction and Re-inspection
S2.6.1
If any part of a vehicle does not comply with the Rules, or is otherwise deemed to be a concern, then
the team must correct the problem and have the car re-inspected.
S2.6.2
The judges and inspectors have the right to re-inspect any vehicle at any time during the competition
and require correction of non-compliance.
S2.7
Inspection Stickers
Inspection stickers issued following the completion of any part of Technical Inspection will be
placed on the upper nose of the vehicle as specified in T13.4 “Technical Inspection Sticker Space”.
Inspection stickers are issued contingent on the vehicle remaining in the required condition
throughout the competition. Inspection stickers may be removed from vehicles that are not in
compliance with the Rules or are required to be re-inspected.
ARTICLE S3
PRESENTATION EVENT
S3.1
Presentation Event Objective – Project Management
S3.1.1
The objective of the Formula Hybrid presentation event is to evaluate the team’s ability to structure
and execute a project management plan that meets the team’s goals. Teams must convince a review
board that the team’s project has been carefully planned, effectively and dynamically executed.
Comment: The environment for engineers and the nature of engineering careers are changing in
essential ways. The issues with which engineers engage have become more and more
multidimensional, and engineers’ expected proficiencies now include project and professional skills.
The Presentation Event requires participants to consider wider communication, planning and team
management principles critical to career success as well as an understanding of financial, ethical,
societal and global issues, beyond the usual technical competencies.
For guidance and specific examples see Appendix K Application of the Project Management
Method to Formula Hybrid.
S3.1.2
The judges should be regarded as a project management or executive review board.
S3.1.3
Evaluation Criteria - Presentations will be evaluated on the contents, including project planning
and change management. Presentation organization and visual aids as well as the presenters’
delivery, timing and the team’s response to questions will also be evaluated.
The presentation must relate to the car entered into the competition although the actual quality of the
vehicle will not be considered as part of the presentation judging.
See Appendix C: Presentation Judging Form.
The Presentation is worth fifty (50) points toward the team’s overall presentation score.
S3.2
Submission Requirements
S3.2.1
Project Plan - Judging will start with a Project Plan before the event.
Each formula hybrid team is required to submit a formal project plan that reflects their goals and
objectives for the upcoming competition, the structure and tasks that will be completed to
accomplish these objectives, and the time schedule over which these tasks will be performed. The
topics covered in the project plan should include:
115
© 2014 SAE International
Rev. 2 - October 15, 2014
(a)
Scope: What will be accomplished, goals and objectives, major deliverables and milestones
(b)
Structure: Organization of the project team, Work Breakdown Structure, project schedule
(c)
Expected Results: “measures of success”, quantifiable attributes used to determine the extent
to which the goals and objectives have been achieved
(d)
Change Management Process: system designed by the team for administering project
change
This Project Plan must consist of at least (1) page and not exceed three (3) pages of text.
Appendixes may be attached to the back of the Project Plan.
Note 1: Appendixes do not count as “pages”.
Note 2: Submittal of the Project Plan is due soon after registration closes. See the Formula Hybrid
website page rules and deadlines http://www.formula-hybrid.org/students/rules-and-deadlines for
the exact due date.
The Project Plan is worth forty (40) points toward the team’s overall presentation score.
S3.2.2
Interim Progress Report - The second submission for judging is an Interim Progress Report.
Following completion and acceptance of the formal project plan, the project team begins the
execution phase. During this phase, members of the project team and other stakeholders must be
updated periodically on progress being made and on issues identified that put the project schedule at
risk. This is done by issuing progress reports at cut-off times selected by the project manager.
These reports are not lengthy but are intended to clearly and concisely communicate to others the
status of the project. The progress report is also a way to document changes to the project scope and
plan that have been approved using the change management process. The topics covered in the
progress report should include:
(a)
Scope: Deliverables and milestones achieved, if not explain; revised project plan if changes
were made
(b)
Structure: Performance against schedule, estimate of status (on schedule); verify major
accomplishments (data, descriptions, photographs); major barriers encountered, approaches to
overcome challenges
(c)
Expected Results: Comparison of actual versus expected results at the project midpoint; if
necessary, actions being taken to get project back on schedule
(d)
Change Management Process: Number of change(s) requests made, number approved;
effectiveness of the change management process, revision made to the process
The Interim Progress Report must not exceed one (1) page. Appendixes may be attached to the
back of the Progress Report. Note that appendixes do not count as “pages”.
The Interim Progress Report is worth ten (10) points toward the team’s overall presentation score.
S3.3
Submission Formats
The Project Plan and Interim Progress Reports must be submitted electronically in separate Adobe
Acrobat™ Format files (*.pdf file). These documents must each be a single file (text, drawings, and
optional content).
These Report files must be named as follows: carnumber_schoolname_Project Plan.pdf and
carnumber_schoolname_Progress Report.pdf using the SAE assigned car number and the complete
school name, e.g.:
116
© 2014 SAE International
Rev. 2 - October 15, 2014
999_University of SAE_Project Plan.pdf
999_University of SAE_Progress Report.pdf
S3.4
Submission Deadlines
The Project Plan and Interim Progress Report must be submitted by the date and time shown in the
Action Deadlines. (See A9.2). Submission instructions are in section A9.4
You will receive confirmation of receipt via email and submissions will be posted on the event
website once report is reviewed for accuracy. Teams should have a printed copy of this reply
available at the competition as proof of submission in the event of discrepancy.
S3.5
Penalty for Late Submission or Non-Submission
See section A9.3 for late submission penalties.
S3.6
Presentation Schedule
S3.6.1
Presentations will be made on the static events day. Presentation times will be scheduled by the
organizers and either, or both, posted in advance on the competition website or released during onsite registration.
S3.6.2
Teams that fail to make their presentation during their assigned time period will receive zero (0)
points for that section of the event.
S3.7
Presentation Format
S3.7.1
One or more team members will give the presentation to the judges. It is strongly suggested,
although not mandated, that the project manager accompany the presentation team. All team
members who will give any part of the presentation, or who will respond to the judges’ questions,
must be in the podium area when the presentation starts and must be introduced to the judges. Team
members who are part of this “presentation group” may answer the judge’s questions even if they
did not speak during the presentation itself.
S3.7.2
Presentations are limited to a maximum of ten (10) minutes. Teams may use hand-outs, posters, etc.
to convey information relevant to their project management case that cannot be contained within a
10-minute presentation.
S3.7.3
The judges will stop any presentation exceeding ten minutes. The presentation itself will not be
interrupted by questions. Immediately following the presentation there will be a question and
answer session of up to five (5) minutes. Only judges may ask questions. Only team members who
are part of the “presentation group” may answer the judges’ questions.
S3.7.4
Formula Hybrid may record a team’s presentation for publication or educational purposes.
However, no recorded presentation will be made public any earlier than 13 months after the event at
which it was recorded. Students have the right to opt out of being recorded - however they must
notify the chief presentation judge in writing prior to the beginning of their presentation.
S3.8
Data Projection Equipment
S3.8.1
Projection equipment is provided by the organizers. Teams are advised to bring their own computer
equipment in the event the organizer’s equipment malfunctions or is not compatible with their
presentation software.
S3.9
Scoring Formula
The scoring of the event is based on the average of the presentation judging forms.
117
© 2014 SAE International
Rev. 2 - October 15, 2014
Where:
Pmax is the highest point score awarded to any team in your vehicle category
Pyour is the point score awarded to your team
Notes:
1.
It is intended that the scores will range from near zero (0) to one hundred (100) to provide
good separation.
2.
The Presentation Event Captain may at his/her discretion, normalize the scores of different
judging teams.
3.
Penalties associated with late submittals (see A9.3 “Late Submission Penalties”) are applied
after the scores are normalized up to a maximum of the teams normalized Presentation Score.
ARTICLE S4
S4.1
DESIGN EVENT
Design Event Objective
The concept of the design event is to evaluate the engineering effort that went into the design of the
car (or the substantial modifications to a prior year car), and how the engineering meets the intent of
the market. The car that illustrates the best use of engineering to meet the design goals and the best
understanding of the design by the team members will win the design event.
Comment: Teams are reminded that FH is an engineering design competition and that in the Design
event, teams are evaluated on their design. Components and systems that are incorporated into the
design as finished items are not evaluated as a student designed unit, but are only assessed on the
team’s selection and application of that unit. For example, teams that design and fabricate their own
shocks are evaluated on the shock design itself as well as the shock’s application within the
suspension system. Teams using commercially available shocks are evaluated only on selection and
application within the suspension system.
S4.2
Submission Requirements
S4.2.1
Design Report - Judging will start with a Design Review before the event.
The principal document submitted for the Design Review is a Design Report. This report must not
exceed eight (8) pages, consisting of not more than four (4) pages of text, three (3) pages of
drawings (see S4.4, “Vehicle Drawings”) and one (1) optional page containing content to be defined
by the team (photos, graphs, etc…).
This document should contain a brief description of the vehicle with the majority of the report
specifically addressing only the engineering, design features, and vehicle concepts new for this
year's event. Include a list of different analysis and testing techniques (FEA, dynamometer testing,
etc.).
Evidence of this analysis and back-up data should be brought to the competition and be available,
on request, for review by the judges. These documents will be used by the judges to sort teams into
the appropriate design groups based on the quality of their review.
Comment: Consider your Design Report to be the “resume of your car”.
S4.2.2
Sustainability Report – The Sustainability Report is a separate document to be submitted at the
same time as the Design Report. This report will contribute to the team’s overall design score and
118
© 2014 SAE International
Rev. 2 - October 15, 2014
may be used as partial criteria for an efficiency award given out by one of the sponsors. The report
should be no longer than one page, including text, diagrams and formulas, and be submitted as a
separate .pdf file.
S4.2.3
Design Spec Sheet - In addition to the above documents, a completed FH Design Spec Sheet must
also be submitted. The FH Design Spec Sheet template can be found on the FH website. (See
ARTICLE A10). Do not alter or re-format the template prior to submission.
The design judges realize that final design refinements and vehicle development may cause the
submitted figures to diverge slightly from those of the completed vehicle. For specifications that are
subject to tuning, an anticipated range of values may be appropriate.
The Design Report, Sustainability Report and the Design Spec Sheet, while related documents,
should stand alone and be considered three (3) separate submissions. Three separate file
submissions are required.
S4.3
Sustainability Requirement
S4.3.1
Sustainability is an oft used, but ill-defined objective of minimizing a product’s impact on the
environment. One of the ways to quantify sustainability is to calculate or measure the CO2
generated by a vehicle. Two techniques for automobiles are common, LCA (Life Cycle Analysis)
and WTW (Well To Wheels) analysis. Although LCA is more comprehensive, a WTW analysis is
easier to perform and nearly as useful, accounting for approximately 80% of an automobile’s
lifetime CO2 emissions.
S4.3.2
CO2 reduction is one justification for transitioning to alternative powertrains or fuels. To properly
compare and contrast various design and fuel options, FH is requiring a one page sustainability
report analysis as part of the design report. This analysis consists of three parts:
(a) Calculation of the CO2 generated in the production and delivery of each MJ of fuel used by the
vehicle (well to tank).
(b) Calculation of the CO2 generated by the vehicle per km of the endurance race (tank to wheels)
(c) A discussion of how sustainability and efficiency objectives affected the engineering and design
decision process. For example, how did the team’s performance and efficiency targets influence
the type of energy storage, its capacity and liquid fuel choice?
S4.3.3
For part S4.3.2(a) teams are encouraged to use public databases to calculate CO2 generated during
the production and delivery of all fuels used by the vehicle. Do not include factors for land use
change and reference all sources.
S4.3.4
For part S4.3.2(b) calculate vehicle fuel consumption and CO2 emissions generated during the
endurance event as defined for the current year. (See ARTICLE D7). Reference all sources and use
only publically available vehicle simulation models. This can be done by modeling or extrapolation
of vehicle test data.
S4.3.5
At a minimum, provide the following data for parts S4.3.2(a) & S4.3.2(b)
CO2 generated in fuel production
Delivery efficiency – from plant to battery or tank
Fuel consumption
Total CO2 generated
Electricity
CO2/MJ
%
MJ/km
kg/km
Fuel
CO2/MJ
%
MJ/km
kg/km
Table 19 – Minimum Sustainability Data Requirements
119
© 2014 SAE International
Rev. 2 - October 15, 2014
S4.3.6
The Sustainability Report is worth thirty (30) points - 15 points for parts S4.3.2(a) and S4.3.2(b)
and 15 points for part S4.3.2(c) - toward the team’s overall design score.
S4.4
Vehicle Drawings
S4.4.1
The Design report must include all of the following drawings:
(a) One set of 3 view drawings showing the vehicle from the front, top, and side.
(b) A schematic of the high voltage wiring showing the wiring between the major components. (See
section EV9.1)
(c) A wiring diagram superimposed on a top view of the vehicle showing the locations of all major
high voltage components and the routing of high voltage wiring.
S4.5
Submission Formats
S4.5.1
The Design and Sustainability Reports must be submitted electronically in separate Adobe
Acrobat™ Format files (*.pdf file). These documents must each be a single file (text, drawings, and
optional content). These Report files must be named as follows: carnumber_schoolname_Design.pdf
and carnumber_schoolname_Sustain.pdf using the SAE assigned car number and the complete
school name, e.g.:
999_University of SAE_Design.pdf
999_University of SAE_Sustain.pdf
S4.5.2
Design Spec Sheets must be submitted electronically in Microsoft Excel™ Format. The format of
the Spec Sheet MUST NOT be altered. Similar to the Design Report, the Design Spec Sheet file
must be named as follows: carnumber_schoolname_Specs.xls (or .xlsx) using the Formula Hybrid
assigned car number and the complete school name, e.g.
999_University of SAE_Specs.xls (or)
999_University of SAE_Specs.xlsx
WARNING – Failure to exactly follow the above submission requirements may result in exclusion
from the Design Event. If your files are not submitted in the required format or are not properly
named then they cannot be included in the documents provided to the design judges and your team
will be excluded from the event.
S4.6
Excess Size Design Reports
If a team submits a Design Report that exceeds four (4) pages of text, three (3) pages of drawing and
one (1) optional page, then only the first four pages of text, three pages of drawings and first
optional page will be read and evaluated by the judges. Note: If included, cover sheets and tables of
contents will count as text pages.
S4.7
Submission Deadlines
The Design Report and the Design Spec Sheets must be submitted by the date and time shown in the
Action Deadlines. (See A9.2). Submission instructions are in section A9.4
You will receive confirmation of receipt via email and/or the event website once report is reviewed
for accuracy. Teams should have a printed copy of this reply available at the competition as proof of
submission in the event of discrepancy.
120
© 2014 SAE International
Rev. 2 - October 15, 2014
S4.8
Penalty for Late Submission or Non-Submission
See section A9.3 for late submission penalties.
S4.9
Penalty for Unsatisfactory Submissions
S4.9.1
At the discretion of the judges, teams that submit a Design Report or a Design Spec Sheet which is
deemed to be unsatisfactory, will not compete in the design event, but may receive between five (5)
and twenty (20) points for their efforts.
S4.9.2
Failure to fully document the changes made for the current year’s event to a vehicle used in prior
FH events, or reuse of any part of a prior year design report are just two examples of Unsatisfactory
Submissions
S4.10
Vehicle Condition
Cars must be presented for design judging in finished condition, i.e. fully assembled, complete and
ready-to-run. The judges will not evaluate any car that is presented at the design event in what they
consider to be an unfinished state. Unfinished cars that are refused judging will receive zero (0)
points for design. Point penalties may be assessed for cars with obvious preparation issues, e.g.
notably loose or missing fasteners.
Note 1: Cars can be presented for design judging without having passed technical inspection, even
if final tuning and setup is in progress.
Note 2: Registered teams that have been unable to complete their vehicles may declare themselves
as “Static events only” at event sign-in and may participate in Design and Presentation events with
whatever design materials or components they wish to present. (See A7.5.3)
S4.11
Judging Criteria
The design judges will evaluate the engineering effort based upon the team’s Design Report, Spec
Sheet, responses to questions and an inspection of the car. The design judges will inspect the car to
determine if the design concepts are adequate and appropriate for the application (relative to the
objectives set forth in the rules). It is the responsibility of the judges to deduct points on the design
judging form, as given in Appendix F, if the team cannot adequately explain the engineering and
construction of the car.
S4.12
Judging Sequence
The actual format of the design event may change from year to year as determined by the organizing
body. Formula Hybrid Design Judging will normally involve two parts:
(a) Initial judging of all vehicles
(b) Final judging ranking the top 2 to 4 vehicles.
121
© 2014 SAE International
Rev. 2 - October 15, 2014
S4.13
Scoring Formula
The scoring of the event is based on either the average of the scores from the Design Judging Forms
(see Appendix D) or the consensus of the judging team.
Where: Pmax is the highest point score awarded to any team in your vehicle category
Pyour is the point score awarded to your team
Notes:
1. It is intended that the scores will range from near zero (0) to two hundred (200) to provide good
separation.
2. The Design Event Captain may at his/her discretion normalize the scores of different judging teams.
3. Penalties applied during the Design Event (see Appendix D “Design Judging Form - Miscellaneous”)
are applied before the scores are normalized.
4. Penalties associated with late submittals (see A9.3 “Late Submission Penalties”) are applied after the
scores are normalized up to a maximum of the teams normalized Design Score.
S4.14
Support Materials
Teams may bring with them to the Design Event any photographs, drawings, plans, charts, example
components or other materials that they believe are needed to support the presentation of the vehicle
and the discussion of the their development process.
122
© 2014 SAE International
Rev. 2 - October 15, 2014
PART D - DYNAMIC EVENTS
ARTICLE D1
D1.1
DYNAMIC EVENTS GENERAL
Maximum Scores
Event
Acceleration
Autocross
Endurance
Total
Hybrid
150 Points
150 Points
400 Points
700 Points
Electric
75 Points
150 Points
400 Points
625 Points
Table 20 – Dynamic Event Maximum Scores
D1.2
Driving Behavior
During the Formula Hybrid Competition, any driving behavior that, in the opinion of the Event
Captain, the Director of Operations or the Clerk of the Course, could result in potential injury to an
official, worker, spectator or other driver, will result in a penalty.
Depending on the potential consequences of the behavior, the penalty will range from an
admonishment, to disqualification of that driver from all events, to disqualification of the team from
that event, to exclusion of the team from the Competition.
D1.3
Safety Procedures
D1.3.1
Drivers must properly use all required safety equipment at all times while staged for an event, while
running the event and while stopped on track during an event. Required safety equipment includes
all drivers gear and all restraint harnesses.
D1.3.2
In the event it is necessary to stop on track during an event the driver must attempt to position the
vehicle in a safe position off of the racing line.
D1.3.3
Drivers must not exit a vehicle stopped on track during an event until directed to do so by an event
official. An exception to this is if there is a fire or a risk of fire due to fuel leakage and/or electrical
problems.
D1.4
Vehicle Integrity and Disqualification
D1.4.1
During the Dynamic Events, the mechanical and electrical integrity of the vehicle must be
maintained. Any vehicle condition that could compromise vehicle integrity, e.g. damaged
suspension, brakes or steering components, electrical failure13, or any condition that could
compromise the track surface, e.g. fluid leaks or dragging bodywork, will be a valid reason for
exclusion by the officials.
D1.4.2
Dynamic events may not be run with a disabled electrical system. The electrical systems must be
functional as indicated by an illuminated TSAL to enter or continue in any dynamic event.
D1.4.3
If vehicle integrity is compromised during the Endurance Event, scoring for that segment will be
terminated as of the last completed lap.
13
Extinguishing of the TSAL will be interpreted as indicative of an electrical failure.
123
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE D2
WEATHER CONDITIONS
The organizer reserves the right to alter the conduct and scoring of the competition based on
weather conditions.
ARTICLE D3
RUNNING IN RAIN
A vehicle may not be operated in damp (D3.1(b)) or wet (D3.1(c)) conditions unless Rain Certified.
(See section EV7.3)
D3.1
Operating Conditions
The following operating conditions will be recognized at Formula Hybrid:
(a) Dry – Overall the track surface is dry.
(b) Damp – Significant sections of the track surface are damp.
(c) Wet – The entire track surface is wet and there may be puddles of water.
(d) Weather Delay/Cancellation – Any situation in which all, or part, of an event is delayed,
rescheduled or canceled in response to weather conditions.
D3.2
Decision on Operating Conditions
The operating condition in effect at any time during the competition will be decided by the
competition officials.
D3.3
Notification
If the competition officials declare the track(s) to be "Damp" or "Wet",
(a) This decision will be announced over the public address system, and
(b) A sign with either "Damp" or "Wet" will be prominently displayed at both the starting line(s)
and the start-finish line of the event(s), and the entry gate to the "hot" area.
D3.4
Tire Requirements
The operating conditions will determine the type of tires a car may run as follows:
(a) Dry – Cars must run their Dry Tires, except as covered in D3.8.
(b) Damp – Cars may run either their Dry Tires or Rain Tires, at each team’s option.
(c) Wet – Cars must run their Rain Tires.
D3.5
Event Rules
All event rules remain in effect.
D3.6
Penalties
All penalties remain in effect.
D3.7
Scoring
No adjustments will be made to teams' times for running in "Damp" or "Wet" conditions. The
minimum performance levels to score points may be adjusted if deemed appropriate by the officials.
124
© 2014 SAE International
Rev. 2 - October 15, 2014
D3.8
Tire Changing
D3.8.1
During the Acceleration or Autocross Events:
Within the provisions of D3.4 above, teams may change from Dry Tires to Rain Tires or vice versa
at any time during those events at their own discretion.
D3.8.2
During the Endurance Event: Teams may change from Dry to Rain Tires or vice versa at any time
while their car is in the staging area inside the "hot" area.
All tire changes after a car has received the "green flag" to start the Endurance Event must take
place in the Driver Change Area.
(a) If the track was "Dry" and is declared "Damp":
(i) Teams may start on either Dry or Rain Tires at their option.
(ii) Teams that are on the track when it is declared "Damp", may elect, at their option, to pit in
the Driver Change Area and change to Rain Tires under the terms spelled out below in "Tire
Changes in the Driver Change Area".
(b) If the track is declared "Wet":
(i) A Red Flag will be shown at the Start/Finish Line and all cars will enter the Driver Change
Area.
(ii) Those cars that are already fitted with "Rain" tires will be allowed restart without delay
subject to the discretion of the Event Captain/Clerk of the Course.
(iii) Those cars without "Rain" tires will be required to fit them under the terms spelled out
below in "Tire Changes in the Driver Change Area". They will then be allowed to re-start at
the discretion of the Event Captain/Clerk of the Course.
(c) If the track is declared "Dry" after being "Damp" or "Wet":
The teams will NOT be required to change back to “Dry” tires.
(d) Tire Changes at Team's Option:
(i)
Within the provisions of D3.4 above and D3.8 below, a team will be permitted to change
tires at their option.
(ii) If a team elects to change from “Dry” to “Rain” tires, the time to make the change will
NOT be included in the team’s total time.
(iii) If a team elects to change from “Rain” tires back to “Dry” tires, the time taken to make the
change WILL be included in the team’s total time for the event, i.e. it will not be
subtracted from the total elapsed time. However, a change from “Rain” tires back to “Dry”
tires will not be permitted during the driver change.
(iv) To make such a change, the following procedure must be followed:
1. Team makes the decision,
2. Team has tires and equipment ready near Driver Change Area,
3. The team informs the Event Captain/Clerk of the Course they wish their car to be
brought in for a tire change,
4. Officials inform the driver by means of a sign or flag at the checker flag station,
5. Driver exits the track and enters the Driver Change Area in the normal manner.
(e) Tire Changes in the Driver Change Area:
125
© 2014 SAE International
Rev. 2 - October 15, 2014
(i)
Per Rule D7.13.3 no more than three people for each team may be present in the Driver
Change Area during any tire change, e.g. a driver and two crew or two drivers and one
crew member.
(ii) No other work may be performed on the cars during a tire change.
(iii) Teams changing from "Dry" to "Rain" tires will be allowed a maximum of ten (10)
minutes to make the change.
(iv) If a team elects to change from "Dry" to "Rain" tires during their scheduled driver change,
they may do so, and the total allowed time in the Driver Change Area will be increased
without penalty by ten (10) minutes.
(v) The time spent in the driver change area of less than 10 minutes without driver change will
not be counted in the team's total time for the event. Any time in excess of these times will
be counted in the team's total time for the event.
ARTICLE D4
DRIVER LIMITATIONS
D4.1
Two Event Limit
D4.1.1
An individual team member may not drive in more than two (2) events.
Note: A minimum of two (2) drivers is required to participate in all of the dynamic events. A
minimum of four (4) drivers is required to participate in all possible runs in all of the dynamic
events.
D4.1.2
It is the team’s option to participate in any event. The team may forfeit any runs in any performance
event.
D4.1.3
In order to drive in the endurance event, a driver must have attended the mandatory drivers meeting
and walked the endurance track with an official.
D4.1.4
The time and location of the meeting and walk-around will be announced at the event.
ARTICLE D5
D5.1
ACCELERATION EVENT
Acceleration Objective
The acceleration event evaluates the car’s acceleration in a straight line on flat pavement.
D5.2
Acceleration Procedure
The cars will accelerate from a standing start over a distance of 75 m (82 yards) on a flat surface.
The foremost part of the car will be staged at 0.30 m (11.8 inches) behind the starting line. A green
flag will be used to indicate the approval to begin, however, time starts only after the vehicle crosses
the start line. There will be no particular order of the cars in the event. A driver has the option to
take a second run immediately after the first.
D5.3
Acceleration Event
D5.3.1
Electric Vehicles: Electric vehicles may make up to three acceleration runs. The fastest run will be
the recorded acceleration time. It is permissible for one driver to make all the acceleration runs.
D5.3.2
Hybrids: Hybrids will have two sets of acceleration runs. The first set must be run electric-only,
with the engine shut off. The second set may be done in any configuration the team chooses.
Hybrids have the option of making up to two additional runs in each category (electric-only and
unrestricted) for a total of up to 6 runs. The fastest run in each category will be the recorded
acceleration time. It is permissible for one driver to make all the acceleration runs.
126
© 2014 SAE International
Rev. 2 - October 15, 2014
D5.4
Tire Traction – Limitations
Special agents that increase traction may not be added to the tires or track surface and “burnouts”
are not allowed.
D5.5
Acceleration Scoring
The acceleration score is based upon the corrected elapsed time. Elapsed time will be measured
from the time the car crosses the starting line until it crosses the finish line.
D5.6
Acceleration Penalties
D5.6.1
Cones Down Or Out (DOO)
A two (2) second penalty will be added for each DOO (including entry and exit gate cones) that
occurred on that particular run to give the corrected elapsed time.
D5.6.2
Off Course
An Off Course (OC) will result in a DNF for that run.
D5.7
Did Not Attempt
The organizer will determine the allowable windows for each event and retains the right to adjust
for weather or technical delays. Cars that have not run by the end of the event will be scored as a
Did Not Finish (DNF).
D5.8
Acceleration Scoring Formula
D5.8.1
There are three sets of runs in the acceleration event; two Hybrid and one Electric with each scored
separately.
The equation below is used to determine the scores for the acceleration event. The first term on the
right represents “performance” points and the second last term represents “participation” points, or
the minimum score for having successfully completed the event.
(
)
(
)
Where:
Tyour is the lowest corrected elapsed time (including penalties) recorded by your team.
Tmin is the lowest corrected elapsed time (including penalties) recorded by the fastest team in
your vehicle category.
Notes:
a) All three acceleration events are scored separately resulting in a different Tmin for each.
b) Negative “performance” points will not be given. However, 15 points will be given for a car
that completes a run, even if Tyour exceeds 10 seconds.
c) DNF = zero (0) points
127
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE D6
D6.1
AUTOCROSS EVENT
Autocross Objective
The objective of the autocross event is to evaluate the car's maneuverability and handling qualities
on a tight course without the hindrance of competing cars. The autocross course will combine the
performance features of acceleration, braking, and cornering into one event.
D6.2
Autocross Procedure
D6.2.1
There will be four (4) Autocross-style heats, with each heat having a different driver. Three (3)
timed laps will be run (weather and time permitting) by each driver and the best lap time will stand
as the time for that heat.
D6.2.2
The car will be staged such that the front wheels are 6 m (19.7 feet) behind the starting line. The
timer starts only after the car crosses the start line.
D6.2.3
There will be no particular order of the cars to run each heat but a driver has the option to take a
second run immediately after the first.
D6.2.4
The organizer will determine the allowable windows for each event and retains the right to adjust
for weather or technical delays. Cars that have not run by the end of the event will be scored as a
Did Not Finish (DNF).
D6.3
Autocross Course Specifications & Speeds
D6.3.1
The following specifications will suggest the maximum speeds that will be encountered on the
course. Average speeds should be 40 km/hr (25 mph) to 48 km/hr (30 mph).
(a) Straights: No longer than 60 m (200 feet) with hairpins at both ends (or) no longer than 45 m
(150 feet) with wide turns on the ends.
(b) Constant Turns: 23 m (75 feet) to 45 m (148 feet) diameter.
(c) Hairpin Turns: Minimum of 9 m (29.5 feet) outside diameter (of the turn).
(d) Slaloms: Cones in a straight line with 7.62 m (25 feet) to 12.19 m (40 feet) spacing.
(e) Miscellaneous: Chicanes, multiple turns, decreasing radius turns, etc. The minimum track
width will be 3.5 m (11.5 feet).
D6.3.2
The length of each run will be approximately 0.805 km (1/2 mile) and the driver will complete a
specified number of runs.
D6.4
Autocross Penalties
The cars are judged on elapsed time plus penalties. The following penalties will be added to the
elapsed time:
D6.4.1
Cone Down or Out (DOO)
Two (2) seconds per cone, including any after the finish line.
D6.4.2
Off Course
Driver must re-enter the track at or prior to the missed gate or a twenty (20) second penalty will be
assessed. Penalties will not be assessed for accident avoidance or other reasons deemed sufficient by
the track officials.
If a paved road edged by grass or dirt is being used as the track, e.g. a go kart track, four (4) wheels
off the paved surface will count as an "off course". Two (2) wheels off will not incur an immediate
penalty; however, consistent driving of this type may be penalized at the discretion of the event
officials.
128
© 2014 SAE International
Rev. 2 - October 15, 2014
D6.4.3
Missed Slalom
Missing one or more gates of a given slalom will be counted as one "off-course" per occurrence.
Each occurrence will incur a twenty (20) second penalty.
D6.4.4
Stalled & Disabled Vehicles
If a car stalls and cannot restart without external assistance, the car will be deemed disabled. Cars
deemed disabled will be cleared from the track by the track workers. At the direction of the track
officials team members may be instructed to retrieve the vehicle. Vehicle recovery may only be
done under the control of the track officials.
D6.5
Corrected Elapsed Time
The elapsed time plus any penalties from that specific run will be used as the corrected elapsed time.
Cars that are unable to complete the course with an average speed of 80% of the fastest car will not
be awarded “performance” points. This means that any autocross time in excess of 125% of the
fastest time will receive no “performance” points.
D6.6
Best Run Scored
The time required to complete each run will be recorded and the team’s best corrected elapsed time
will be used to determine the score.
D6.7
Autocross Scoring Formula
The equation below is used to determine the score for the autocross event. The first term represents
“performance” points, and last term represents “participation” points or the minimum score for
having successfully completed the event.
(
)
(
)
Where:
Tmin is the lowest corrected elapsed time (including penalties) recorded by the fastest team in
your vehicle category over their four heats.
Tmax is 125% of Tmin.
Tyour is the lowest corrected elapsed time (including penalties) recorded by your team over the
four heats.
Notes:
(a) A DNF in all four heats will score zero (0) points.
(b) Negative “performance” points will not be given. However, 30 points will be given for a car
that completes a run, even if Tyour exceeds Tmax.
129
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE D7
D7.1
ENDURANCE EVENT
Right to Change Procedure
The following are general guidelines for conducting the endurance event. The organizers reserve the
right to establish procedures specific to the conduct of the event at the site. All such procedures will
be made known to the teams through newsletters, or the Formula Hybrid website, or on the official
bulletin board at the event.
D7.2
Endurance Objective
The endurance event is designed to evaluate the vehicle’s overall performance, reliability and
efficiency. Unlike fuel economy tests that result in vehicles going as slow as possible in order to
use the least amount of fuel, Formula Hybrid rewards the team that can cover a designated distance
on a fixed amount of energy in the least amount of time.
D7.3
Endurance General Procedure
D7.3.1
In general, the team completing the most laps in the shortest time will earn the maximum points
available for this event. Formula Hybrid uses an endurance scoring formula that rewards both speed
and distance traveled. (See D7.18)
D7.3.2
The endurance distance is approximately 44km (27.34 miles) comprised of four (4) 11 km (6.84
mile) segments.
D7.3.3
Driver changes will be made between each segment.
D7.3.4
Wheel to wheel racing is prohibited.
D7.3.5
Passing another vehicle may only be done in an established passing zone or under the control of a
course marshal.
D7.4
Endurance Course Specifications & Speeds
Course speeds can be estimated by the following course specifications. Average speed should be 48
km/hr (29.8 mph) to 57 km/hr (35.4 mph) with top speeds of approximately 105 km/hr (65.2 mph).
Endurance courses will be configured, where possible, in a manner which maximizes the advantage
of regenerative braking.
(a) Straights: No longer than 77.0 m (252.6 feet) with hairpins at both ends (or) no longer than
61.0 m (200.1 feet) with wide turns on the ends. There will be passing zones at several
locations.
(b) Constant Turns: 30.0 m (98.4 feet) to 54.0 m (177.2 feet) diameter.
(c) Hairpin Turns: Minimum of 9.0 m (29.5 feet) outside diameter (of the turn).
(d) Slaloms: Cones in a straight line with 9.0 m (29.5 feet) to 15.0 m (49.2 feet) spacing.
(e) Minimum Track width: The minimum track width will be 4.5 m (14.76 feet).
(f) Miscellaneous: The organizers may include chicanes, multiple turns, decreasing radius turns,
elevation changes, etc.
D7.5
Energy
D7.5.1
All vehicles competing in the endurance event must complete the event using only the energy stored
on board the vehicle at the start of the event plus any energy reclaimed through regenerative braking
during the event.
D7.5.2
Prior to the beginning of the endurance event, all competitors may charge their electric
accumulators from any power source they wish.
130
© 2014 SAE International
Rev. 2 - October 15, 2014
D7.5.3
Once a vehicle has begun the endurance event, recharging accumulators from an outside source is
not permitted.
D7.6
Hybrid Vehicles
D7.6.1
All Hybrid vehicles will begin the endurance event with the same amount of energy on board.
D7.6.2
The amount of energy allotted to each team is determined by the Formula Hybrid Rules Committee
and is listed in Table 1 – 2015 Energy and Accumulator Limits
D7.6.3
The fuel allocation for each team is based on the tables in Appendix A, adjusted downward by an
amount equal to the stated energy capacity of the vehicle’s accumulator(s).
D7.6.4
There will be no extra points given for fuel remaining at the end of the endurance event.
D7.7
Fueling - Hybrid Vehicles
D7.7.1
Prior to the beginning of the endurance event, the vehicle fuel tank and any downstream fuel
accumulators, e.g., carburetor float bowls, will be drained. The allocated amount of fuel will then
be added to the tank by the organizers and the filler will be sealed.
D7.7.2
Once fueled, the vehicle must proceed directly to the endurance staging area.
D7.8
Charging - Electric Vehicles
Each Electric vehicle will begin the endurance event with whatever energy can be stored in its
accumulator(s), given the accumulator capacity limitations in Table 1.
D7.9
Endurance Run Order
Endurance run order will be determined by the team’s corrected elapsed time in the autocross.
Teams with the best autocross corrected elapsed time will run first. If a team did not score in the
autocross event, the run order will then continue based on acceleration event times, followed by any
vehicles that may not have completed either previous dynamic event. Endurance run order will be
published at least one hour before the endurance event is run.
D7.10
Entering the Track
At the start of the event and after driver changes, vehicles will be directed to enter the track by the
starter based on traffic conditions.
D7.11
Endurance Vehicle Restarting
D7.11.1 The vehicle must be capable of restarting without external assistance at all times once the vehicle
has begun the event.
D7.11.2
If a vehicle stops out on the track, it will be allowed one (1) lap by the vehicle that is following it
(approximately one (1) minute) to restart.
D7.11.3 At the end of Driver Change, the vehicle will be allowed two (2) minutes to reenergize the
electrical system and restart the vehicle drive system (See: D7.13.8).
D7.11.4
If restarts are not accomplished within the above times, the vehicle will be deemed disabled and
scored as a DNF for the event.
D7.12
Breakdowns & Stalls
D7.12.1 If a vehicle breaks down it will be removed from the course and will not be allowed to re-enter the
course.
D7.12.2 If a vehicle spins, stalls, ingests a cone, etc., it will be allowed to restart and re-enter the course
where it went off, but no work may be performed on the vehicle
131
© 2014 SAE International
Rev. 2 - October 15, 2014
D7.12.3 If a vehicle stops on track and cannot be restarted without external assistance, the track workers will
push the vehicle clear of the track. At the discretion of event officials, two (2) team members may
retrieve the vehicle under direction of the track workers.
D7.13
Endurance Driver Change Procedure
D7.13.1 There must be a minimum of two (2) drivers for the endurance event, with a maximum of four (4)
drivers. One driver may not drive in two consecutive segments.
D7.13.2 Each driver will drive an 11 km (6.83 miles) segment, and then be signaled into the driver change
area.
D7.13.3 Only three (3) team members, including the driver or drivers, will be allowed in the driver change
area. Only the tools necessary to adjust the vehicle to accommodate the different drivers and/or
change tires will be carried into this area (no tool chests etc.). Extra people entering the driver
change area will result in a twenty (20) point penalty to the final endurance score for each extra
person entering the area.
Note: Teams are permitted to “tag-team” in and out of the driver change area as long as there are no
more than three (3) team members present at any one time.
D7.13.4 The vehicle must come to a complete stop, the IC engine turned off and the TSV shut down. These
systems must remain shut down until the new driver is in place. (See D7.13.8)
D7.13.5 The driver will exit the vehicle and any necessary adjustments will be made to the vehicle to fit the
new driver (seat cushions, head restraint, pedal position, etc.). The new driver will then be secured
in the vehicle.
D7.13.6 Three (3) minutes are allowed for the team to change drivers. The time starts when the vehicle
comes to a halt in the driver change area and stops when the correct adjustment of the driver
restraints and safety equipment has been verified by the driver change area official. Any time taken
over the allowed time will incur a penalty. (See D7.17.2(k))
D7.13.7 Other than changes required to accommodate each driver or covered by D3.8 “Tire Changing”, the
team is not permitted to perform any work on the vehicle during driver change. .
D7.13.8 Once the new driver is in place and an official has verified the correct adjustment of the driver
restraints and safety equipment, a maximum of two (2) minutes are allowed to re-energize the
electrical system, restart the vehicle drive system and begin moving out of the driver change area.
D7.13.9 The process given in D7.13.2 through D7.13.8 will be repeated for each 11 km (6.83 mile) segment.
The vehicle will continue until it completes the total 44 km (27.34 miles) distance or until the
endurance event track closing time, at which point the vehicle will be signaled off the course.
D7.13.10 The driver change area will be placed such that the timing system will see the driver change as an
extra-long lap. Unless a driver change takes longer than three (3) minutes, this extra-long lap will
not count into a team’s final time. If a driver change takes longer than three minutes, the extra time
will be added to the team’s final time.
D7.14
Endurance Lap Timing
D7.14.1 Each lap of the endurance event will be individually timed either by electronic means, or by hand.
D7.14.2 Each team is required to time their vehicle during the endurance event as a backup in case of a
timing equipment malfunction. An area will be provided where a maximum of two team members
can perform this function. All laps, including the extra-long laps must be recorded legibly and
turned in to the organizers at the end of the endurance event. Standardized lap timing forms will be
provided by the organizers.
132
© 2014 SAE International
Rev. 2 - October 15, 2014
D7.15
Exiting the Course
D7.15.1 Timing will stop when the vehicle crosses the start/finish line.
D7.15.2 Teams may elect to shut down and coast after crossing the start/finish line, but must fully enter the
driver change area before coming to a stop. There will be no “cool down” laps.
D7.15.3 The speed limit when entering the shut-down area is 15 MPH. Excessive speed will be penalized.
D7.16
Endurance Minimum Speed Requirement
D7.16.1 A car's allotted number of laps must be completed in a maximum of 120 minutes elapsed time from
the start of that car's first lap.
Cars that are unable to comply will be flagged off the course and their actual completed laps tallied.
D7.16.2 If a vehicle’s lap time becomes greater than Max Average Lap Time (See: D7.18) it may be declared
“out of energy”, and flagged off the course. The vehicle will be deemed disabled and scored as a
DNF for the event.
Note: Teams should familiarize themselves with the Formula Hybrid endurance scoring formulas.
Attempting to complete additional laps at too low a speed can cost a team points.
D7.17
Endurance Penalties
D7.17.1 Penalties will not be assessed for accident avoidance or other reason deemed sufficient by the track
official.
D7.17.2 The penalties in effect during the endurance event are listed below.
(a) Cone down or out (DOO)
Two (2) seconds per cone. This includes cones before the start line and after the finish line.
(b) Off Course (OC)
For an OC, the driver must re-enter the track at or prior to the missed gate or a twenty (20)
second penalty will be assessed.
If a paved surface edged by grass or dirt is being used as the track, e.g. a go kart track, four (4)
wheels off the paved surface will count as an "off course". Two (2) wheels off will not incur an
immediate penalty. However, consistent driving of this type may be penalized at the discretion
of the event officials.
(c) Missed Slalom
Missing one or more gates of a given slalom will incur a twenty (20) second penalty.
(d) Failure to obey a flag
Penalty: 1 minute
(e) Over Driving (After a closed black flag)
Penalty: 1 Minute
(f) Vehicle to Vehicle Contact
Penalty: DISQUALIFIED
(g) Running Out of Order
Penalty: 2 Minutes
(h) Mechanical Black Flag
133
© 2014 SAE International
Rev. 2 - October 15, 2014
See D7.23.3(b). No time penalty. The time taken for mechanical inspection under a “mechanical
black flag” is considered officials’ time and is not included in the team’s total time. However, if
the inspection reveals a mechanical integrity problem the vehicle may be deemed disabled and
scored as a DNF for the event.
(i) Reckless or Aggressive Driving
Any reckless or aggressive driving behavior (such as forcing another vehicle off the track,
refusal to allow passing, or close driving that would cause the likelihood of vehicle contact) will
result in a black flag for that driver.
When a driver receives a black flag signal, he/she must proceed to the penalty box to listen to a
reprimand for his/her driving behavior.
The amount of time spent in the penalty box will vary from one (1) to four (4) minutes
depending upon the severity of the offense.
If it is impossible to impose a penalty by a stop under a black flag, e.g. not enough laps left, the
event officials may add an appropriate time penalty to the team’s elapsed time.
(j) Inexperienced Driver
The Chief Marshall/Director of Operations may disqualify a driver if the driver is too slow, too
aggressive, or driving in a manner that, in the sole opinion of the event officials, demonstrates
an inability to properly control their vehicle. This will result in a DNF for the event.
(k) Driver Change
Driver changes taking longer than three (3) minutes will be penalized.
D7.18
Endurance Scoring Formula
D7.18.1 The scoring for the endurance event will be based upon the total laps completed, the on-track
elapsed time for all drivers (less the uncharged extra-long laps for the driver changes, change to wet
tires, etc.), plus any penalty time and penalty points assessed against all drivers and team members.
Vehicles scored as a DNF for the event will get credit for all laps completed prior to the DNF
The equation below is used to determine the score for the endurance event. The first term represents
“performance” points, and the last term represents “participation” points, or the minimum score for
having successfully completed all or part of the event.
(
( )
( )
)
(
)
(
)
Where:
Max Average Lap Time = 120 / the number of laps required to complete 44 km.
Tmin = the lowest corrected average lap time (including penalties) recorded by the fastest team
in your vehicle category over their completed laps.
Tyour = the corrected average lap time (including penalties) recorded by your team over your
completed laps.
134
© 2014 SAE International
Rev. 2 - October 15, 2014
LapSum(n)max = The value of LapSum corresponding to number of complete laps credited to
the team in your vehicle category that covered the greatest distance.
LapSum(n)your = The value of LapSum corresponding to the number of complete laps credited
to your team
Notes:
(a)
If your team completes all of the required laps, then LapSum(n)your will equal the maximum
possible value of LapSum(n). (990 for a 44 lap event).
(b)
If your team does not complete the required number of laps, then LapSum(n)your will be based
on the number of laps completed. See Appendix B for LapSum(n) calculation methodology.
(c)
Negative “performance points” will not be given. However, 80 points will be given for a car
that completes at least one (1) lap, even if Tyour exceeds the Max Average Lap Time.
D7.18.2 Teams exceeding 120 minutes elapsed time will have their results truncated at the last lap completed
within the 120 minute limit.
D7.19
Post Event Engine and Energy Check
The organizer reserves the right to impound any vehicle immediately after the event to check
accumulator capacity, engine displacement (method to be determined by the organizer) and
restrictor size (if fitted).
D7.20
Endurance Event – Driving
D7.20.1 During the endurance event when multiple vehicles are running on the course it is paramount that
the drivers strictly follow all of the rules and driving requirements. Aggressive driving, failing to
obey signals, not yielding for passing, etc. will result in a black flag and a discussion in the penalty
box with course officials. The amount of time spent in the penalty box is at the discretion of the
officials and is included in the run time. Penalty box time serves as a reprimand as well as informing
the driver of what he/she did wrong. Drivers should be aware that contact between open wheel
racers is especially dangerous because tires touching can throw one vehicle into the air.
D7.20.2 Endurance is a timed event in which drivers compete only against the clock not against other
vehicles. Aggressive driving is unnecessary.
D7.21
Endurance Event – Passing
D7.21.1 Passing during the endurance event may only be done in the designated passing zones and under the
control of the track officials. Passing zones have two parallel lanes – a slow lane for the vehicles
that are being passed and a fast lane for the vehicles that are making a pass. On approaching a
passing zone a slower leading vehicle will be blue flagged and must shift into the slow lane and
decelerate. The following faster vehicle will continue in the fast lane and make the pass. The vehicle
that had been passed may reenter traffic only under the control of the passing zone exit marshal.
The passing lanes, e.g. the slow lanes, may be either to the left or the right of the fast lane depending
on the design of the specific course.
D7.21.2 These passing rules do not apply to vehicles that are passing disabled vehicles on the course or
vehicles that have spun out and are not moving. When passing a disabled or off-track vehicle it is
critical to slow down, drive cautiously and be aware of all the vehicles and track workers in the area.
D7.21.3 Under normal driving conditions when not being passed all vehicles use the fast lane.
135
© 2014 SAE International
Rev. 2 - October 15, 2014
D7.22
Endurance Event – Driver’s Course Walk
The endurance course will be available for walk by drivers prior to the event. All endurance drivers
should walk the course before the event starts.
D7.23
Flags
D7.23.1 The flag signals convey the commands described below, and must be obeyed immediately and
without question.
D7.23.2 There are two kinds of flags for the competition: Command Flags and Informational Flags.
Command Flags are just that, flags that send a message to the competitor that the competitor must
obey without question. Informational Flags, on the other hand, require no action from the driver, but
should be used as added information to help him or her maximize performance. What follows is a
brief description of the flags used at the competitions in North America and what each flag means.
Note: Not all of these flags are used at all competitions and some alternate designs are occasionally
displayed. Any variations from this list will be explained at the drivers meetings.
Table 21 - Flags
D7.23.3 Command Flags
(a)
BLACK FLAG - Pull into the penalty box for discussion with the Director of Operations or
other official concerning an incident. A time penalty may be assessed for such incident.
(b)
MECHANICAL BLACK FLAG (Black Flag with Orange Dot) (“Meatball”) - Pull into the
penalty box for a mechanical inspection of your vehicle, something has been observed that
needs closer inspection.
(c)
BLUE FLAG - Pull into the designated passing zone to be passed by a faster competitor or
competitors. Obey the course marshal’s hand or flag signals at the end of the passing zone to
merge into competition.
(d)
CHECKER FLAG - Your segment has been completed. Exit the course at the first
opportunity after crossing the finish line.
136
© 2014 SAE International
Rev. 2 - October 15, 2014
(e)
GREEN FLAG - Your segment has started, enter the course under direction of the starter.
NOTE: If you are unable to enter the course when directed, await another green flag as the
opening in traffic may have closed.
(f)
RED FLAG - Come to an immediate safe controlled stop on the course. Pull to the side of the
course as much as possible to keep the course open. Follow course marshal’s directions.
(g)
YELLOW FLAG (Stationary) - Danger, SLOW DOWN, be prepared to take evasive action,
something has happened beyond the flag station. NO PASSING unless directed by the course
marshals.
(h)
YELLOW FLAG (Waved) - Great Danger, SLOW DOWN, evasive action is most likely
required, BE PREPARED TO STOP, something has happened beyond the flag station, NO
PASSING unless directed by the course marshals.
D7.23.4 Informational Flags
(i)
RED AND YELLOW STRIPED FLAG - Something is on the racing surface that should not
be there. Be prepared for evasive maneuvers to avoid the situation. (Course marshals may be
able to point out what and where it is located, but do not expect it.)
(j)
WHITE FLAG - There is a slow moving vehicle on the course that is much slower than you
are. Be prepared to approach it at a cautious rate.
ARTICLE D8
D8.1
RULES OF CONDUCT
Competition Objective – A Reminder
The Formula Hybrid event is a design engineering competition that requires performance
demonstration of vehicles and is NOT a race. Engineering ethics will apply. It is recognized that
hundreds of hours of labor have gone into fielding an entry into Formula Hybrid. It is also
recognized that this event is an “engineering educational experience” but that it often times becomes
confused with a high stakes race. In the heat of competition, emotions peak and disputes arise. Our
officials are trained volunteers and maximum human effort will be made to settle problems in an
equitable, professional manner.
D8.2
Unsportsmanlike Conduct
In the event of unsportsmanlike conduct, the team will receive a warning from an official. A second
violation will result in expulsion of the team from the competition.
D8.3
Official Instructions
Failure of a team member to follow an instruction or command directed specifically to that team or
team member will result in a twenty five (25) point penalty.
Note: This penalty can be individually applied to all members of a team.
D8.4
Arguments with Officials
Argument with, or disobedience to, any official may result in the team being eliminated from the
competition. All members of the team may be immediately escorted from the grounds.
D8.5
Alcohol and Illegal Material
Alcohol, illegal drugs, weapons or other illegal material are prohibited on the event site during the
competition. This rule will be in effect during the entire competition. Any violation of this rule by a
team member will cause the expulsion of the entire team. This applies to both team members and
faculty advisors. Any use of drugs, or the use of alcohol by an underage individual, will be reported
to the local authorities for prosecution.
137
© 2014 SAE International
Rev. 2 - October 15, 2014
D8.6
Parties
Disruptive parties either on or off-site should be prevented by the Faculty Advisor.
D8.7
Trash Clean-up
D8.7.1
Cleanup of trash and debris is the responsibility of the teams. The team’s work area should be kept
uncluttered. At the end of the day, each team must clean all debris from their area and help with
maintaining a clean paddock.
D8.7.2
Teams are required to remove all of their material and trash when leaving the site at the end of the
competition. Teams that abandon furniture, or that leave a paddock that requires special cleaning,
will be billed for removal and/or cleanup costs.
D8.7.3
All liquid hazardous waste (engine oil, fuel, brake fluid, etc.) must be put in well-marked, capped
containers and left at the hazardous waste collection building. The track must be notified as soon as
the material is deposited by calling the phone number posted on the building. See the map in the
registration packet for the building location.
ARTICLE D9
GENERAL RULES
D9.1
Dynamometer Usage
D9.1.1
If a dynamometer is available, it may be used by any competing team. Vehicles to be dynamometer
tested must have passed all parts of technical inspection.
D9.1.2
Fuel, ignition and drivetrain tuning will be permitted while testing on the dynamometer.
D9.2
Problem Resolution
Any problems that arise during the competition will be resolved through the Operations Center and
the decision will be final.
D9.3
Forfeit for Non-Appearance
It is the responsibility of teams to be in the right place at the right time. If a team is not present and
ready to compete at the scheduled time they forfeit their attempt at that event. There are no makeups for missed appearances.
D9.4
Safety Class – Attendance Required
A safety class is required for all team members. The format and requirements will be posted on the
Formula Hybrid website.
D9.5
Drivers Meetings – Attendance Required
All drivers for an event are required to attend the pre-event drivers meeting(s). The driver for an
event will be disqualified if he/she does not attend the driver meeting for the event.
D9.6
Personal Vehicles
D9.6.1
Personal cars, motorcycles and trailers must be parked in designated areas only. Only FH
competition vehicles will be allowed in the track areas.
All vehicles and trailers must be parked behind the white “Fire Lane” lines.
D9.6.2
Some self-powered transport such as Bicycles and Skate boards are permitted, subject to restrictions
posted in the event guide
D9.7
Self-propelled Pit Carts, Tool Boxes, etc. - Prohibited
The use of self-propelled pit carts, tool boxes, tire carriers or similar motorized devices in any part
of the competition site, including the paddocks, is prohibited.
138
© 2014 SAE International
Rev. 2 - October 15, 2014
ARTICLE D10
D10.1
PIT/PADDOCK/GARAGE RULES
Vehicle Movement
D10.1.1 Vehicles may not move under their own power anywhere outside of an officially designated
dynamic area.
D10.1.2 When being moved outside the dynamic area:
(a) The vehicle TSV must be deactivated.
(b) The vehicle must be pushed at a normal walking pace by means of a “Push Bar” (D10.2).
(c) The vehicle’s steering and braking must be functional.
(d) A team member must be sitting in the cockpit and must be able to operate the steering and
braking in a normal manner.
(e) A team member must be walking beside the car.
(f)
The team has the option to move the car either with
(i) all four (4) wheels on the ground or
(ii) with the rear wheels supported on a dolly or push bar mounted wheels, provided that the
external wheels supporting the rear of the car are non-pivoting such that the vehicle will
travel only where the front wheels are steered.
D10.1.3 Cars with wings are required to have two team members walking on either side of the vehicle
whenever the vehicle is being pushed.
D10.1.4 During performance events when the excitement is high, it is particularly important that the car be
moved at a slow pace in the pits. The walking rule will be enforced and a point penalty of twenty
five (25) points will be assessed for each violation.
D10.2
Push Bar
Each car must have a removable device that attaches to the rear of the car that allows two (2)
people, standing erect behind the vehicle, to push the car around the event site. This device must
also be capable of decelerating, i.e. slowing and stopping the forward motion of the vehicle and
pulling it rearwards. It must be presented with the car at Technical Inspection.
D10.3
Smoking – Prohibited
Smoking is prohibited in all competition areas.
D10.4
Fueling and Refueling
Officials must conduct all fueling and refueling. The vehicle must be de-energized when refueling,
and no other activities (including any mechanical or electrical work) are allowed while refueling.
D10.5
Energized Vehicles in the Paddock or Garage Area
Any time a vehicle is energized and capable of electric motion the drive wheels must be supported
clear of the ground or removed, complying with the requirements of Section D10.6
D10.6
Engine Running in the Paddock
Engines may be run in the paddock provided the car has passed technical inspection and the
following conditions are satisfied:
(a) The car is on an adequate stand, and
(b) The drive wheels are at least 10.2 cm (4 inches) off the ground, or the drive wheels have been
removed.
139
© 2014 SAE International
Rev. 2 - October 15, 2014
D10.7
Safety Glasses
Safety glasses must be worn at all times while working on a vehicle, and by anyone within 10 ft. (3
meters) of a vehicle that is being worked on.
ARTICLE D11
D11.1
DRIVING RULES
Driving Under Power
D11.1.1 Cars may only be driven under power
(a) When running in an event,
(b) When on the practice track
(c) During the brake test
(d) During any powered vehicle movement specified and authorized by the organizers.
D11.1.2 For all other movements cars must be pushed at a normal walking pace using a push bar.
D11.1.3 Driving a vehicle outside of scheduled events or scheduled practice will result in a two hundred
(200) point penalty for the first violation and expulsion of the team for a second violation.
D11.2
Driving Off-Site - Prohibited
Driving off-site is absolutely prohibited. Teams found to have driven their vehicle at an off-site
location during the period of the competition will be excluded from the competition.
D11.3
Practice Track
D11.3.1 A practice track for testing and tuning cars may be available at the discretion of the organizers. The
practice area will be controlled and may only be used during the scheduled practice times.
D11.3.2 Practice or testing at any location other than the practice track is absolutely forbidden.
D11.3.3 Cars using the practice track must have passed all parts of the technical inspection.
D11.4
Situational Awareness
Drivers must maintain a high state of situational awareness at all times and be ready to respond to
the track conditions and incidents. Flag signals and hand signals from course marshals and officials
must be immediately obeyed.
ARTICLE D12
DEFINITIONS
DOO - A cone is “Down or Out”—if the cone has been knocked over or the entire base of the cone
lies outside the box marked around the cone in its undisturbed position.
DNF- Did Not Finish
Gate - The path between two cones through which the car must pass. Two cones, one on each side
of the course define a gate: Two sequential cones in a slalom define a gate.
Entry Gate -The path marked by cones which establishes the required path the vehicle must take to
enter the course.
Exit Gate - The path marked by cones which establishes the required path the vehicle must take to
exit the course.
140
© 2014 SAE International
Rev. 2 - October 15, 2014
Staging Area - An area prior to the entry to an event for the purpose of gathering those cars that are
about to start.
OC - A car is Off Course if it does not pass through a gate in the required direction.
141
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix A
Accumulator Rating & Fuel Equivalency
Each accumulator device will be assigned a fuel equivalency based on the following:
Note: C, Vnom, Vpeak and Ah are device nameplate values at the 2C (0.5 hour) rate. To convert from
manufacturer’s data at other hour-rates, Peukert’s equation should be used (see below).
Batteries:
Capacitors:
Energy (Wh)  (Vnom )( Ah)(0.8)
 C (V peak 2  Vmin 2 ) 
 / 3600
Energy (Wh)  


2


where Vmin is assumed to be 10% of Vpeak.
Table 22 – Accumulator Device Energy Calculations
Wh / Liter14
Liquid Fuels
Gasoline (Sunoco15 Optima)
Biodiesel (B100)
Ethanol (Sunoco E-85R)
2,343
2,500±16
1,718
Table 23 – Fuel Energy Equivalencies
For example, using 89 Maxwell MC 2600 ultracaps (2600 F, 2.7 V), the fuel equivalency would be 2.606 Wh
per device, or 231.9 Wh for a bank of 89, resulting in a 99cc reduction of gasoline or 135cc reduction of E-85.
Peukert's Equation
The Peukert equation models how the capacity of a battery changes with its rate of discharge:
C0.5 / Cn = (I0.5 / In)P
Where:
C0.5 is the capacity at the 0.5 hour rate
Cn is the capacity at the “n” hour rate
I0.5 is the current at the 0.5 hour rate
In is the current at the “n” hour rate, and
P is the “Peukert Number” which can be scaled from discharge curves
for the battery when plotted on logarithmic axes.
14
Formula Hybrid assumes a mechanical efficiency of 27%
Full specifications for Sunoco racing fuels may be found at: http://www.racegas.com/fuel/compare
16
Because BioDiesel can vary seasonally and between suppliers, the diesel fuel provided at the competition will have been tested for
energy content and the allocations adjusted accordingly.
15
142
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix B
Determination of LapSum(n) Values
The parameter LapSum(n) is used in the calculation of the scores for the endurance event. It is a
function of the number of laps (n) completed by a team during the endurance event. It is calculated
by summing the lap numbers from 1 to (n), the number of laps completed. This gives increasing
weight to each additional lap completed during the endurance event.
For example:
If your team is credited with completing five (5) laps of the endurance event, the value of
LapSum(n)your used in compute your endurance score would be the following:
LapSum(5)your = 1 + 2 + 3 + 4 + 5 = 15
Number of Laps
Completed (n)
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Number of Laps
Completed (n)
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
LapSum(n)
0
1
3
6
10
15
21
28
36
45
55
66
78
91
105
120
136
153
171
190
210
231
253
LapSum(n)
276
300
325
351
378
406
435
465
496
528
561
595
630
666
703
741
780
820
861
903
946
990
Table 24 - Example of LapSum(n) calculation for a 44-lap Endurance event
143
© 2014 SAE International
Rev. 2 - October 15, 2014
LapSum(n) vs. Number of Laps Completed
1000
900
800
LapSum(n)
700
600
500
400
300
200
100
0
0
5
10
15
20
25
30
35
40
45
Laps Completed
Figure 35 - Plot of LapSum(n) calculation for a 44-lap Endurance event
144
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix C
Presentation Judging Form
Note: This form is not final. The final presentation judging form will be posted on the Formula
Hybrid website prior to the competition.
CAR NUMBER: ___________ SCHOOL: ____________________________________________
Judge Team: ____________
Judge #: ___________
Score the following categories on the basis of the maximum possible score for each category.
The following table is a suggested guide.
Percentage 0 25 50 75 100
1. PROJECT PLAN (0-40):
This report was to be submitted to FH by December 22nd, 2014.
0 10 20 30 40
2. INTERIM PROGRESS REPORT (0-10):
This report was to be submitted to FH by February 18th, 2015.
0 3
3. PRESENTATION (0-50):
0 13 25 38 50
5
8
10
Scope: What will be accomplished, goals and objectives
Structure: Organization of project team, Work Breakdown Structure (WBS)
Expected Results: Measure of success, which goals/objectives were
achieved
Effective Change Management: System designed to handle project change
Lessons Learned: What would team do differently and why?
VISUAL AIDS, TIMING & DELIVERY :
Were visual aids used? Did the presenter speak in a clear voice? Did the
presenter show enthusiasm and promote confidence in the technical aspects?
Did he/she maintain eye contact?
QUESTIONS:
Did the answers illustrate that the team fully understood the questions?
Promote complete confidence in their response to the questions?
PRESENTATION POINTS (100 points maximum)
Total: ______________
145
© 2014 SAE International
Rev. 2 - October 15, 2014
Presentation content scoring:
Not Present
0%
Scope
Advanced
100%
Some aspects
are explained
and defined
Most aspects are
clearly
explained and
defined
Every aspect is clearly
explained and defined
No written
explanation
Limited
explanation
Nearing
completion of
explanation
with a roughly
organized WBS
Explanation is
mostly complete
with sufficiently
organized WBS
Complete explanation
and well organized with
clearly defined WBS
Missing or
incomplete
Described with a
basic
understanding
Mostly accurate
Accurate
Meets and exceeds
expectations
Insignificantly
effective
Moderately
effective
Nearing
effective
Very effective
Extremely effective
process
Could not
articulate issues
encountered in
process
Half-hearted
attempt to
describe issues
and/or solutions
Issues defined,
explained
actions taken to
correct
problems
Clearly,
identified issues,
articulated
corrective action
taken and
benefits
Clear, thoughtful and
professional evaluation
of obstacles, how
handled, to what effect
and further
improvements
considered for 2016
Measures of success,
quantifiable attributes
to determine which
goals and objectives
have been achieved
Effective Change
Management
Process
Proficient
75%
Aspects are
incomplete and
lack definition
Organization of team
and WBS
Expected Results
Developing
50%
Scope is absent
What will be
accomplished, goals
and objectives
Structure
Novice
25%
System designed for
administering project
change
Lessons Learned
Total
/50
COMMENTS: (Continue on other side if necessary.)
146
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix D
Design Judging Form17
SCHOOL ________________________________ CAR NUMBER __________
DESIGN PROCESS – The most common question to the students from the design judges is “Why?” For each
subsystem of the car the team should be able to clearly and quickly state:
a) The design objectives.
b) What the design must do to achieve the objectives (functions).
c) The performance requirements (design specifications) that quantify how well the design must
perform the required functions.
d) How well the final design meets the requirements based on both engineering analyses and
testing. (No points are directly associated with this item, but the judges will expect the
students to demonstrate their understanding of the design process as they address each of the
items below.)
The judges will consider the following factors when assigning scores to each of the scored items.
a) SAFETY
b) Reliability – the winner is usually found among the finishers.
c) Manufacturing and assembly - Were manufacturing and ease of assembly considered during
design?
d) Serviceability – Are items that require frequent inspection, service, or adjustment easily
accessible?
e) Innovation – Does the car include innovative features?
NOTE TO JUDGES: Judges with limited expertise in any area may insert an ‘X’ in that sections score. The chief
Design Judge will scale the remaining scores so that the omitted score will not penalize the team.
17
This form is for informational use only – the actual form used may differ. Check the Formula Hybrid website prior to
the competition for the latest Design judging form.
147
© 2014 SAE International
Rev. 2 - October 15, 2014
CHASSIS & SUSPENSION
__________ CHASSIS (0-20)
What are the requirements for the chassis design? Are load paths direct and short? Are components sized properly for the
loads? Were weight distribution and C.G. height optimized?
__________ COCKPIT & HUMAN FACTORS (0-10)
Is the vehicle designed to accommodate & function with a wide variety of body sizes? Are controls and instruments easy
to use? Are electrical systems well isolated? Does the design consider occupant safety beyond the requirements?
__________ SUSPENSION (0-25)
What were the requirements for suspension design? How were kinematics, lateral load transfer, adjustability, etc.
addressed? How was vehicle handling developed?
__________ BRAKES (0-10)
How was the brake system designed?
__________ STEERING (0-10)
How was the steering system designed?
POWERTRAIN
__________ POWERTRAIN SYSTEM ARCHITECTURE (0-25)
Was the balance between I.C. engine and electric drive well thought out. What were the resulting requirements? How
does the system architecture relate to scoring points in the FH competition?
__________ POWERTRAIN ELECTRICAL (0-25)
Are the accumulator, power electronics, and electrical machine well matched? What were the requirements for the
accumulator/power electronics/electrical machine? Why was this accumulator/power electronics/electrical machine
chosen? How well does the accumulator/power electronics/electrical machine meet the requirements?
__________ POWERTRAIN / MECHANICAL (0-20)
What were the requirements for the IC engine? Was the engine modified (optimized) for the hybrid application?
__________ ELECTRONICS & CONTROLS (0-20) What are the requirements on the electronics and controls
system and what determined these requirements? Did the students design the electronic systems? Is there closed loop
control of the engine? Data acquisition?
GENERAL
__________ SUSTAINABILITY (0 to 30)
Did the team demonstrate an understanding and ability to calculate upstream and vehicle CO2 emissions? How were
sustainability and efficiency objectives incorporated into the design process? Did the team demonstrate an understanding
of how sustainability can impact wide-ranging design decisions? (See Section S4.3)
__________ AESTHETICS & CRAFTSMANSHIP (0-5)
Fit and finish, use of appropriate materials, professional quality fabrication (e.g., wiring routed, loomed, and labeled;
quality of fabrication, welding, machine work), detail work completed. Does the vehicle look attractive?
Does it have a high performance appearance?
__________ MISCELLANEOUS (0 to -50)
If the team does not exhibit a good understanding of the car a penalty may be applied.
__________ TOTAL DESIGN POINTS (200 points maximum)
148
© 2014 SAE International
Rev. 2 - October 15, 2014
DESIGN COMMENTS:
149
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix E
Wire Current Capacity (DC)
Wire AN
gauge
Copper
24
22
20
18
16
14
12
10
8
6
4
3
2
1
0
2/0
3/0
4/0
Wire Area
Max. Fuse
(Thousands Continuous
of circular
Rating
Mils)
5
7
10
14
20
28
40
55
80
105
140
165
190
220
260
300
350
405
250
455
300
505
Table 25 – Wire Current Capacity
150
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix F
Required Equipment
□ Fire Extinguishers
Minimum Requirements
Each team must have at least two (2) 2.3 kg (5 lb.) dry chemical (Min. 3-A:40-B:C) Fire
extinguishers
Extinguishers of larger capacity (higher numerical ratings) are acceptable.
All extinguishers must be equipped with a manufacturer installed pressure/charge gauge.
Special Requirements
Teams must identify any fire hazards specific to their vehicle’s components and if fire
extinguisher/fire extinguisher material other than those required in section T15.1 are needed to
suppress such fires, then at least two (2) additional extinguishers/material (at least 5 lb or equivalent)
of the required type must be procured and accompany the car at all times. As recommendations vary,
teams are advised to consult the rules committee before purchasing expensive extinguishers that may
not be necessary.
□ Chemical Spill Absorbent
Teams must have chemical spill absorbent at hand, appropriate to their specific risks. This material
must be presented at technical inspection.
□ Insulated Gloves
Insulated gloves, rated for at least the voltage in the TSV system, with protective over-gloves.
Electrical gloves require testing by a qualified company. The testing is valid for 14 months after the
date of the test. All gloves must have the test date printed on them.
□ Safety Glasses
Safety glasses must be worn as specified in section D10.7
□ MSDS Sheets
Materials Safety Data Sheets (MSDS) for the accumulator.
□ Additional
Any special safety equipment called for in the MSDS, for example correct gloves recommended for
handling any electrolyte material in the accumulator.
151
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix G
Example TSV Electrical Diagram
Enclosure A
Wire gauge
Manufacturer
Model
Ahr
Cell voltage
N Parallel
N series
Enclosure C
Manufacturer
Model
Rating
Manufacturer
Model
Rating
B+
Motor Controller
Manufacturer M+
Model
B-
Wire Gauge
Enclosure B
Manufacturer
Model
Ahr
Cell voltage
N Parallel
N series
Wire Gauge
M-
Motor
Manufacturer
Model
Rating
ISOLATION
Controls
Ground Fault
Meter
Model #
Manufacturer
Model
152
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix H
Example Relay Latch Circuits
The diagrams below are examples of relay-based latch circuits that can be used to latch the momentary output
of the Bender IMD (either high-true or low-true) such that it will comply with Formula Hybrid rule EV5.1
Note: It is important to confirm by checking the data sheets, that the output pin of the IMD can power the
relay directly. If not, an amplification device will be required.
Figure 36- Latching Circuit for High-True output
Figure 37 - Latching Circuit for Low-True output
153
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix I
SAE Technical Standards included in the CDS Rules
The SAE Technical Standards Board (TSB) has made the following SAE Technical Standards available on
line, at no cost, for use by Collegiate Design teams. Standards are important in all areas of engineering and
we urge you to review these documents and to become familiar will their contents and use
.
The technical documents listed below include both (1) standards that are identified in the rules and (2)
standards that the TSB and the various rules committees believe are valuable references or which may be
mentioned in future rule sets.
All Collegiate Design Series teams registered for competitions in North America have access to all the
standards listed below - including standards not specific to your competition.
Baja SAE
J586 - Stop Lamps for Use on Motor Vehicles Less Than 2032 mm in Overall Width
J759 - Lighting Identification Code
J994 - Alarm - Backup – Electric Laboratory Tests
J1741 - Discriminating Back-Up Alarm Standard
Clean Snowmobile Challenge
J192 - Maximum Exterior Sound Level for Snowmobiles
J1161 - Sound Measurement – Off-Road Self-Propelled Work Machines Operator-Work Cycle
Formula Hybrid
J1318 - Gaseous Discharge Warning Lamp for Authorized Emergency, Maintenance and Service Vehicles
J1673 - High Voltage Automotive Wiring Assembly Design
Formula SAE
SAE 4130 steel is referenced but no specific standard is identified
SAE Grade 5 bolts are required but no specific standard is identified
Supermileage
J586 - Stop Lamps for Use on Motor Vehicles Less Than 2032 mm in Overall Width
SAE Technical Standards for Supplemental Use
Standards Relevant to Baja SAE
J98 – Personal Protection for General Purpose Industrial Machines – Standard
J183 – Engine Oil Performance and Engine Service Classification - Standard
J306 – Automotive Gear Lubricant Viscosity Classification - Standard
J429 – Mechanical and Material Requirements for Externally Threaded Fasteners – Standard
J512 – Automotive Tube Fittings - Standard
J517 – Hydraulic Hose - Standard
J1166 – Sound Measurement – Off-Road Self-Propelled Work Machines Operator-Work Cycle
J1194 – Rollover Protective Structures (ROPS) for Wheeled Agricultural Tractors
154
© 2014 SAE International
Rev. 2 - October 15, 2014
J1362 – Graphical Symbols for Operator Controls and Displays on Off-Road Self-Propelled Work Machines Standard
J1614 – Wiring Distribution Systems for Construction, Agricultural and Off-Road Work Machines
J1703 - Motor Vehicle Brake Fluid - Standard
J2030 – Heavy Duty Electrical Connector Performance Standard
J2402 – Road Vehicles – Symbols for Controls, Indicators and Tell-Tales – Standard
Standards Relevant to Clean Snowmobile Challenge
J44 – Service Brake System Performance Requirements – Snowmobiles - Recommended Practice
J45 – Brake System Test Procedure – Snowmobiles – Recommended Practice
J68 – Tests for Snowmobile Switching Devices and Components - Recommended Practice
J89 – Dynamic Cushioning Performance Criteria for Snowmobile Seats - Recommended Practice
J92 – Snowmobile Throttle Control Systems – Recommended Practice
J192 – Maximum Exterior Sound Level for Snowmobiles - Recommended Practice
J288 – Snowmobile Fuel Tanks - Recommended Practice
J1161 – Operational Sound Level Measurement Procedure for Snowmobiles - Recommended Practice
J1222 – Speed Control Assurance for Snowmobiles - Recommended Practice
J1279 – Snowmobile Drive Mechanisms - Recommended Practice
J1282 – Snowmobile Brake Control Systems - Recommended Practice
J2567 – Measurement of Exhaust Sound Levels of Stationary Snowmobiles - Recommended Practice
Standards Relevant to Formula SAE
J183 – Engine Oil Performance and Engine Service Classification - Standard
J306 – Automotive Gear Lubricant Viscosity Classification - Standard
J429 – Mechanical and Material Requirements for Externally Threaded Fasteners – Standard
J452 - General Information – Chemical Compositions, Mechanical and Physical Properties of SAE Aluminum
Casting Alloys – Information Report
J512 – Automotive Tube Fittings - Standard
J517 – Hydraulic Hose - Standard
J637 – Automotive V-Belt Drives – Recommended Practice
J829 – Fuel Tank Filler Cap and Cap Retainer
J1153 - Hydraulic Cylinders for Motor Vehicle Brakes – Test Procedure
J1154 – Hydraulic Master Cylinders for Motor Vehicle Brakes - Performance Requirements - Standard
J1703 - Motor Vehicle Brake Fluid - Standard
J2045 – Performance Requirements for Fuel System Tubing Assemblies - Standard
J2053 – Brake Master Cylinder Plastic Reservoir Assembly for Road Vehicles – Standard
Standards Relevant to Formula Hybrid
J1772 – SAE Electric Vehicle and Plug in Hybrid Conductive Charge Coupler
Standards Relevant to all CDS Competitions
J1739 – Potential Failure Mode and Effects Analysis in Design (Design FMEA) Potential Failure Mode and
Effects Analysis in Manufacturing and Assembly Processes (Process FMEA) and Potential Failure Mode and
Effects Analysis for Machinery (Machinery FMEA)
155
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix J
Firewall Equivalency Test
To demonstrate equivalence to the aluminum sheet specified in rule T4.5.2, teams should submit a
video, showing a torch test of their proposed firewall material.
Camera angle, etc. should be similar to the video found here: http://youtu.be/njQHjOy6ZYI
The torch must be a Mapp gas torch such as a Bernzomatic (Mapp/Map gas) TS8000, TS4000 or
equivalent.
The torch should be held at a distance from the test piece such that the hottest part of the flame (the
tip of the inner cone) is just touching the test piece.
The video must show two sequential tests and be contiguous and unedited (except for trimming the
irrelevant leading and trailing portions).
The first part of the video should show the torch applied to a piece of Aluminum of the thickness
called for in T4.5.2, and held long enough to burn through the aluminum. The torch should then be
moved directly to a similarly sized test piece of the proposed material without changing any settings,
and held for at least as long as the burn-through time for the Aluminum.
There must be no penetration of the test piece.
156
© 2014 SAE International
Rev. 2 - October 15, 2014
Appendix K
Application of the Project Management Method to
Formula Hybrid
Introduction
Engineering design and development projects are complex. The Formula Hybrid vehicle program is such a
project. To complete these types of projects successfully, a structured, disciplined process for moving forward
must be used. The project team must proceed in an orderly way during project execution rather than react to
each situation that arises. Resources are limited and a set completion date must be met; resources and time
cannot be wasted if project success is to be achieved. And success is normally defined as meeting the
specifications and goals of the project, on-time, within the allocated budget. Application of the Project
Management method is expected to improve the construction and compliance of the cars developed along with
promoting effective teamwork throughout the competition.
Benefit of Project Management
Project management is a method for bringing discipline to a design and development effort throughout the
four phases of the project life cycle. Figure 1 gives an overview of the project life cycle and the major
supporting activities for each phase. Once a proposed project is approved to begin, the project manager
initiates the planning process in which the project is more clearly defined and a path for successful completion
is created. During the execution phase the project manager monitors the completion of project tasks. When
challenges or barriers are encountered the project manager intervenes and develops a revised plan that will
once again lead the team members toward achieving project goals despite these problems. During the final
phase, when the project is completed, the focus is upon continuous improvement. A debriefing session is
conducted by the project manager with the team to identify the strengths of the plan and weaknesses that need
correction for future projects.
A reoccurring weakness of many projects is the inability to maintain accurate documentation and keep all
team members aligned with the most current “plan of record” during project execution. All project plans are
created with some level of uncertainty; unanticipated events will occur and new knowledge gained during
execution which will require a change in project scope or plan. To accommodate these situations, a disciplined
change management process is used to ensure that all project team members are working to the same
requirements and schedule despite changes that are being made. By using this process, at project completion
all documentation will accurately reflect what was actually constructed. Thus, a key component of the project
execution phase is a change management process designed to be compatible with the team’s method of
operation.
157
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 1 – Project Life Cycle
Project management requires the team to “think” and “strategize” before beginning a design and development
effort. Time is allocated before the project execution begins to plan a course of action. This is counter to the
natural tendency, when facing tight deadlines for challenging projects, to “stop wasting time” and “do
something”. Without a project plan, the team members “react” to situations that frequently lead to lost time,
wasted resources, and overlooking specifications that must be met for compliance.
Project Management
Project management is not a bureaucratic process, but a structure that is intended to help the project team
succeed. It is designed to assist the project team not hinder it. If project management becomes an obstacle,
then the process is not designed correctly and must be re-engineered by the project team.
An effective project management process requires some documentation, but not a large quantity of
documentation. As a disciplined process, strict adherence to due dates, deliverables, milestones, and change
management is a necessity. If it appears that any of these items may be in jeopardy, the project manager must
be notified immediately. If deadlines are missed or specifications cannot be met, the project manager must
create a recovery plan that gets the project back on track using a change management process. The constraints
of time, resources, and budget will influence the decisions made during the execution phase. Unfortunately, at
times these constraints may affect the ability of the team to meet all of the project goals and objectives. When
this occurs, the team must make a decision on what will be retained and what goals will be abandoned. But,
this is the result of discussion and a conscious decision rather than the result of “whatever happens” at the end
of the project.
158
© 2014 SAE International
Rev. 2 - October 15, 2014
1. PROJECT PLANNING
The plan is the road map to successful project completion. Project execution should not be started without a
well-defined, achievable plan. Projects started with an incomplete plan, but the intention of completing it at a
later date when the project team acquires a greater understanding, usually fail. They needlessly consume
resources and waste time on tasks that do not help achieve the project goals. The project manager’s first
priority is leading the project team members in developing an acceptable project plan.
To create a project plan, information is needed regarding four different areas: (1) scope of the project, (2)
tasks or activities that must be completed, (3) roles and responsibilities of the project team members, (4)
project schedule. Once a project has been approved, three standard types of project documents are generated
that summarize the information needed for creating the plan; Statement of Work, Work Breakdown Structure,
and Work Packages. With inputs received from members of the project team, the project manager develops the
entire project plan.
Project Scope: Statement of Work
Statement of Work (SOW) is a short description of the project. It is also referred to as the project scope and
must be completed before significant planning of activities or tasks can occur. A meaningful SOW can be
written in less than 2 pages. Information contained includes:
A. Reason for the Project: In a business setting this is usually associated with (1) increasing revenue, (2)
reducing cost, (3) strategic objectives. In Formula Hybrid “strategic objectives” of the team or
individual members would most likely be the reason for competing.
B. Project Objectives: The goals and objectives are usually answers to the question: as a team what are
we trying to achieve in this year’s competition, beyond winning? These can be secondary goals such
as increasing performance of the car, testing new components or technologies, improving overall team
performances. The stated objectives should be a standard against which decisions made throughout the
project are measured. When selecting from among alternatives; the team must ask: how does this
choice move us closer to achieving our objectives?
C. Sponsor of the Project: the company, organizational, or individual sponsors have objectives for own
involvement ; the objectives of the sponsors must also be considered in defining project scope
D. Project Manager: Accountable for success of the project; even though members of the team have
responsibilities contributing to the successful completion of the project, the Project Manager is
accountable for bringing the project to a successful completion. Therefore, the Project Manager
collaborates with the Project Team Leader to arrive at a consensus on how to proceed with project
planning and execution.
E. Key Project Deliverables, Milestones: These items define the pathway to successful completion.
F. Expected Results: These items are “measures of success” helpful in determining to what extent the
project goals and objectives were achieved. They are used at project completion to assess if it was a
success, partial success or failure.
Typically when an engineering project has been finished, the project manager conducts a debriefing
session with project team members to identify what worked well during project execution and areas of
weakness where improvement is needed. A root-cause analysis is performed to identify improvement
opportunities for future projects. The “expected results” criteria are used to focus the deliberations
during the debriefing session.
The project scope, SOW, describes at a high level the work that is to be done and the goals and objectives of
the project. This work, and only this work, should be performed unless the scope is officially modified using
the team’s change management process. During project execution, the project scope is the “stake in the
ground” serving as a guide to all team members operating in the fast paced, sometimes chaotic environment
159
© 2014 SAE International
Rev. 2 - October 15, 2014
typical during project execution. When a decision must be made immediately by a team member, and there is
insufficient time to consult with other members of the team, the decision should be made considering how it
supports the goals and objectives defined in the SOW.
Formula Hybrid Program: SOW Considerations
Formula Hybrid Program Objectives: Design and build a formula hybrid race car with superior on-track
performance
Design Constraints: Meet the specified design guidelines and safety standards
Project Constraints: Time schedule, budget, technical expertise, resources
One obvious objective of the Formula Hybrid project is to win the competition, the overarching goal. But
there can be additional secondary goals that should be included in the SOW so they are not forgotten when
establishing priorities or making decisions during project execution. These could be perfecting the design of
last year’s car, strengthening sub-systems that failed or performed poorly, testing the endurance of a new
component or sub-system, introducing a completely new design, introducing a new technology to determine if
it enhances performance and is durable.
Seldom is a breakthrough product developed with all aspects being an entirely new design. Technology based
products usually evolve with the progressive introduction of new technologies or features into existing designs
that ultimately lead to an entirely new product with capabilities not available in the past.
2. PROJECT STRUCTURE
Organization
A project is conducted within an organizational structure to enable the efficient use of resources. Traditionally,
a large organization is partitioned into an arrangement of independent components, which decentralizes
responsibilities and promotes distributed decision making. When the partitions are created around functions,
this is called a functional organization. Projects are supported in this type of organization by assigning
specialists to work groups focused on completing an assigned task. When they are done, they are reassigned to
another project.
A project team is an alternative to the functional work group. A team is an interdisciplinary group of
individuals who are responsible not only for their own assignment but for the success of the entire team.
Team members frequently assist others in an effort to complete tasks and advance the project forward, even if
a task is outside their area of expertise. Reassignment of team members is not done until the entire project is
completed.
To fully understand a project plan it is necessary to know the organization structure in which it is being
conducted. If either a work group or project team structure is used, there will be a leadership hierarchy created
to manage the project. Each formula hybrid team will have a management structure suitable for its operation.
A schematic of the organization structure should be included in the project plan along with a brief description
of how project management will be performed. Because it is a demanding position, it is recommended that the
Project Manager be someone other than the team captains.
Work Breakdown Structure (WBS)
To make a large project more manageable and increase the probability that all necessary work will be
completed in an orderly manner, a process of “segmentation” is performed dividing the project into smaller
manageable pieces. The WBS is a schematic representation of the pieces of the project, called activities or
tasks. Using a cascading representation, the WBS shows how the pieces fit together to form the structure of
160
© 2014 SAE International
Rev. 2 - October 15, 2014
the total project. It is a tool for planning the detailed execution of the project; it structures the way work will
be performed.
WBS Example:
Your company makes back-plates for vehicle braking systems. Your customer, a major auto manufacturer,
has informed you that a high failure rate of brake systems has been experienced because of corrosion within
the brake wheel unit and severe abrasion of moving parts within the wheel unit.
A Failure Mode Analysis indicates the cause as:
(1) Inadequate drainage of trapped water within the unit
(2) Dull metal cutting tooling that is leaving rough edges on the back-plate stampings
Your customer wants this problem fixed immediately!
A five-level WBS for this project is shown in Figure 2. Levels 1-2 involve administrative functions supporting
the project. Authorization to initiate the project is received at Level 1 “Program”. The project budget, or
resource allocation, is approved at Level 2 “Project”. Identification of the large scale efforts or functional
areas that are needed to complete the project are identified in Level 3 “Tasks”. A sub-division of these broad
activities or responsibilities are shown in Levels 4 and 5, “Sub-Tasks” and “Work Packages”.
The budget and allocated resources approved at the “Project” level are distributed among the Level 5 “Wok
Packages” tasks by the project manager during creation of the project plan. The project team members may
estimate that more resources are needed than what have been allocated. If this occurs, the project manager
adjusts the schedule or project scope until a balance between budget, resources, project scope, and time
schedule is achieved.
161
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 2 – Work Breakdown Structure
WBS Guidance for the Formula Hybrid Competition
Using the example in Figure 1 as reference, the Level 1 “Program” entry could be the Formula Hybrid
Competition. The Level 2 “Project” entry could be a series of sub-projects or focus areas which combined will
cover all the work necessary for the competition. These areas could be aligned with the structure defined in the
organization schematic.
The Level 3 “Tasks” entries could be more specific of the major activities that must be conducted in the subprojects. For example, these could include the following:

Mechanical Design

Electrical Design

Design Optimization

Vehicle Integration

Verification Testing

Quality & Safety Compliance

Performance Optimization
Work Packages (WP)
The Project Manager is responsible for segmenting the project into manageable pieces. The relationship
between these pieces is presented schematically in the WBS. Levels 1-2 are administrative designations, levels
3-5 identify tasks that must be completed. Information needed to create the project plan is obtained from the
most detailed level of the WBS, Level 5 “Work Packages”.
The Project Manager creates Work Packages using four guidelines. A well-defined WP is:
162
© 2014 SAE International
Rev. 2 - October 15, 2014
A. Manageable: Specific responsibilities and deliverables are assigned
B. Independent: Minimum interfaces and dependencies exist with other groups; even though
dependencies are unavoidable
C. Unifiable: Total project can be assembled from the pieces
D. Measurable: Progress and quality in each of the pieces can be determined
The Project Manager assigns WPs to individuals or groups capable of completing the work. A WP is less than
1 page and each person responsible for a WP is required to provide the following information to the Project
Manager. This information is used to create the project schedule, describes resources required, defines
deliverables from the effort, and identifies interdependencies between tasks.

WP Objectives

Budget required

Assigned Responsibilities

Resources Needed

Required Inputs from Predecessor Activities

Time required to Complete WP

Deliverables to Following Activities

Performance Measures
With completion of the SOW, WBS, and all WP information received, the Project Manager can proceed to
developing the project schedule.
Project Scheduling:
The WBS schematically shows the basic project tasks that must be completed and the groups or individuals
responsible for completing those tasks, but it does not provide information on the timeframe in which each
must be performed. Also, because some of these tasks can be performed in parallel, and some must occur
sequentially, the overall project duration cannot be calculated by simply adding up individual task times.
Construction of a Gantt cart will enable the project completion time to be determined graphically along with
the necessary start and finish times for each task. In addition, the Gantt chart serves as a useful tool for
tracking progress during project execution.
The Gantt chart graphically shows the interdependencies between tasks or activities for a project. From the
Gantt chart several important project parameters can be determined:
A. Expected time for project completion
B. Critical activities; if they are delayed the project completion date is pushed-out
C. Activities with slack; they can be delayed, within limits, without affecting the project completion date
D. Start and finish dates for each activity; performing each activity within these specified time intervals
will lead to the overall project being completed on time
In addition, the Gantt chart can be used to plan resource utilization. Using the WPs as a reference, it can show
when specific resources must be available and can be used as a tool for coordinating resource deployment
across the entire project schedule. A staffing profile can be constructed using the WPs and Gantt chart.
163
© 2014 SAE International
Rev. 2 - October 15, 2014
Table 1 lists information needed for creating a schedule for the Disc Brake Modification Project. This
information was extracted from the WPs prepared by the project team members. Duration of each activity is
needed to determine the total completion time of the project. Information on immediate predecessors defines
the interrelationships between activities. Some activities cannot begin before results, or deliverables, are
obtained from an earlier task. Predecessor information affects which activities can be conducted in parallel and
which must be done sequentially.
The Gantt chart for the Disc Brake Modification Project example is shown in Figure 3. It was constructed
using the information from Table 1 and applying the critical path scheduling method.
Activities
Activity Duration (Weeks)
1
2
Critical Path Activities
B
D
3
4
5
6
7
G
A
8
H
Slack 2 Weeks
C
Slack 2 Weeks
E
Slack 1 Week
F
Slack 1 Week
I
Slack 1 Week
Figure 3 - Disc Brake Modification Project
164
© 2014 SAE International
Rev. 2 - October 15, 2014
The schedule shows that the duration of this project is 8 weeks. There are 4 critical path activities; if time
beyond the planned interval is needed to complete any one of these tasks, completion of the entire project will
be delayed beyond 8 weeks. There are also 5 activities with slack ranging from 1 to 2 weeks. If additional time
is used to complete any of these activities, but it is less than the slack value, then there will be no impact to
overall project completion. Slack time provides a time buffer in the project schedule and can be used
selectively to balance the demand for resources during project execution and to compensate for slips in
schedule.
Construction of a Gantt Chart
The Gantt chart can be constructed graphically using an excel spreadsheet. A summary chart similar to the one
shown in Figure 2 is generated through a series of four steps.
Step 1: construct a project schedule when all actives are started at the earliest time possible, a forward
pass.
Step2: construct a schedule when all activities are completed as late as possible, a backward pass.
Step 3: compile a table of activity times from the forward and backward pass schedules; Earliest Start,
Earliest Finish, Latest Start, Latest Finish
Step 4: calculate Slack Time from the activity times in the table; tasks with zero Slack Time are
critical path activities, combine these activities together to define the critical path of the project. But
be aware that it is not unusual for a project to have more than one critical path.
Following are the results from the 4-step process used to construct the Gantt Chart in Figure 3 for the Disc
Brake Modification Project.
Step 1 Forward Pass
Activities
Activity Duration (Weeks)
1
2
3
4
5
6
7
8
A
B
C
D
E
F
G
H
I
Figure 4 - Earliest Start Gantt Chart
Using the activity duration times and precedence relationships given in Table 1, place each activity on the
chart as early as possible while also maintaining the correct precedence between activities. The logic used to
create the early start Gantt chart is given in Table 2.
165
© 2014 SAE International
Rev. 2 - October 15, 2014
Activity
Duration
Precedence Relationship
Earliest Starting Time
A
3 weeks
no predecessor
at project start
B
1 week
no predecessor
at project start
C
2 weeks
must follow A
A ends at week 3, start at week 3
D
3 weeks
must follow B
B ends at week 1, start at week 1
E
2 weeks
must follow B
B ends at week 1, start at week 1
F
2 weeks
must follow B
B ends at week 1, start at week 1
G
3 weeks
must follow D and E
D ends at week 4, E ends at week 3
start at week 4
H
1 week
must follow C and G
C ends at week 5, G ends at week 7
start at week 7
I
4 weeks
must follow F
F ends at week 3, start at week 3
Table 2 – Logic for Constructing the Earliest Start Gantt Chart
The forward pass process is used to determine the Earliest Start, Earliest Finish times for each activity. In
Figure 4, the combined activities give a project completion time of 8 weeks.
Step 2 Backward Pass
The forward pass process is used to determine the total duration of the project. This completion time is used as
the starting point when performing the backward pass process. All actives directly linked to the end of the
project, not another activity, are assigned the project completion time as their Latest Finish time.
The Latest Start Gantt Chart is given in Figure 5. It was constructed using the backward pass process. The
Latest Start and Latest Finish activity times are determined using the backward pass process. Care must be
taken when using the backward pass process because it is easy to be confused.
166
© 2014 SAE International
Rev. 2 - October 15, 2014
Activities
Activity Duration (Weeks)
1
2
3
4
5
6
7
8
A
B
C
D
E
F
G
H
I
Figure 5 – Earliest Start Gantt Chart
The logic used to create the Latest Start Gantt chart is given in Table 3. Starting with the activities directly
linked to the end of the project, define their Latest Finish times as the completion time of the project. Subtract
the duration of each activity to calculate the corresponding Latest Start times for these activities. Then
continue “progressing backwards” by assigning Latest Finish times to activities to the immediate predecessors
of activities already processed.
167
© 2014 SAE International
Rev. 2 - October 15, 2014
Activity
Duration
Precedence Relationship
Latest Finishing Time
I
4 weeks
linked to project end
assign I finish time end of 8, I starts at beginning of week 5
H
1 week
linked to project end
assign H finish time end of 8 week, H starts at beginning of week 8
G
3 weeks
followed by H
H starts at beginning of week 8
G finishes at end of week 7, G starts at beginning of week 5
F
2 weeks
followed by I
I starts at beginning of week 5,
F finishes at end of week 4, F starts at beginning of week 3
E
2 weeks
followed by G
G starts at beginning of week 5
E finishes at end of week 4, E starts at beginning of week 3
D
3 weeks
followed by G
G starts at beginning of week 5
D finishes at end of week 4, D starts at beginning of week 2
C
2 weeks
followed by H
H starts at beginning of week 8
C finishes at end of week 7, C starts at beginning of week 6
B
1 week
followed by F, E, D,
F starts at beginning of week 3, E starts at beginning of week 3,
D starts at beginning of week 2**
thus B must finish at end of week 1
A
3 weeks
followed by C
C starts at beginning of week 6
A finishes at end of week 5, A starts at beginning of week3
Table 3 – Logic for Constructing the Latest Start Gantt Chart
Step 3 Compile Activity Times
The activity times from the Early Start, Latest Start Gantt Charts are summarized in Table 4.
168
© 2014 SAE International
Rev. 2 - October 15, 2014
Activity
A
Earliest Start Earliest Finish
(Weeks)
(Weeks)
0
3
Latest Start
(Weeks)
2
Latest Finish
(Weeks)
5
Slack Time
(Weeks)
2
B
0
1
0
1
0**
C
3
5
5
7
2
D
1
4
1
4
0**
E
1
3
2
4
1
F
1
3
2
4
1
G
4
7
4
7
0**
H
7
8
7
8
**
I
3
7
4
8
1
** Critical Path Activities
Table 4 - Activity Times for the Disc Brake Modification Project
Step 4 Calculate Slack Time, identify Critical Path Activities
Slack Time can be calculated two ways; both methods give the same result:
A. Slack Time = (Latest Finish Time) – (Earliest Finish Time)
B. Slack Time = (Latest Start Time) – (Earliest Start Time)
Slack Times for the Disc Brake Modification Project are given in Table 4. Activities without Slack are Critical
Path Activities. For this project they are:

Activity B
Disassemble Production Tolling

Activity D
Re-Machine Production Tooling

Activity G
Assemble, Recalibrate Tooling

Activity H
Manufacture Prototypes
During project execution these critical path activities must be carefully monitored and controlled to prevent a
delay in project completion. But the other activities must also be monitored. If the available slack time is fully
consumed, these activities can become critical path activities.
The results from this 4 step process have been consolidated into a single Gantt chart for the Disc Brake
Modification Project shown in Figure 2.
3. PROJECT EXECUTION
With the project plan completed and all members of the project team informed of their roles and
responsibilities using the WPs, execution of the project plan can begin. The role of the project manager shifts
at this point from planning to monitoring and control. The primary focus is on directing the project toward a
successful completion; with success defined as meeting the project goals and objectives on-time and within
the budget and resource constraints.
169
© 2014 SAE International
Rev. 2 - October 15, 2014
The Gantt chart constructed during the project planning phase is a good tool for monitoring progress. At any
point during project execution, called the cut-off time, the project manager can call for a report on progress.
Using this cut-off time as a reference, the project team members report on the activities completed, not started,
or those in progress. For activities in progress an estimate of percent complete is needed. The project manager
compares this information to the plan of record and determines if the project is on schedule, behind schedule,
or ahead of schedule.
Recovery Planning
When activities are behind schedule two basic actions should be considered. If additional people with the
correct skills and expertise can be brought into the project, or existing team members can be temporarily
reassigned, increasing the staff working on specific activities will reduce the time interval needed to complete
these activities. By applying additional people to downstream activities, the adverse impact from schedule
over-runs by earlier activities can be reduced or eliminated.
If additional resources cannot be applied, then splitting activities should be a considered. If deliverables from a
predecessor activity are late, splitting downstream activities can allow work to begin on-schedule for tasks that
are not dependent upon these deliverables. This practice will cause some activities that were originally
planned to be performed sequentially to now be performed in parallel with other activities upon which they are
dependent.
Splitting activities introduces a risk into the project because once the deliverables are received it may be
necessary to redo some of the work performed in response to the actual inputs. But, when additional resources
are not available, splitting may be the only way to offset the adverse impact of delays in predecessor activities,
without modifying project scope.
Project Monitoring and Control Example
An example of how to use the Gantt chart to monitor and control a project follows. The project manager for
the Disc Brake Modification Project has called for a read-out of progress at a cut-off time of 4 weeks. Figure 5
shows a summary of the reports received from project team members. The red circles represent the actual
status of each activity; the blue bars represent the planned status of these activities.
170
© 2014 SAE International
Rev. 2 - October 15, 2014
Figure 6 - Disc Brake Modification Project – 4 Week Status Report
A comparison of the planned and actual status of each activity is given in Table 6. From this summary of
project status against plan, it is reasonable to conclude that the project is behind schedule at the 4 week cut-off
point and recovery actions are necessary. Given this situation, the project manager takes “control” of the
project and identifies recovery actions necessary to get the project back on schedule. Because the cut-off time
is midway in the project schedule, there is sufficient time to get the project back on track before the planned
completion. As the project proceeds closer to scheduled completion recovery becomes more difficult or
impossible.
Table 5 lists the recovery actions needed to bring the project back on schedule. They include adding resources,
activity splitting, and using available slack time.
Overall the activities related to tooling improvement are causing the most serious delays. However, even
though it is not a critical path activity, Activity A, creating the modified design, will affect several
downstream activities related to material availability and prototype manufacture. The project manager must
carefully monitor this design activity so that excessive delays will not create a new critical path in the project.
Once decisions are made on the actions to be taken to get the project back on schedule, the project manager
will create a new Gantt chart reflecting new activities created by splitting and reduced durations resulting from
application of additional resources. This then becomes the “plan of record” against which future progress will
be measured.
171
© 2014 SAE International
Rev. 2 - October 15, 2014
Activity
Planned Status
Actual Status
Status Against Plan
Recovery Actions
A
Complete
2/3 Complete
Behind Schedule
B
Complete
Complete
On Schedule
C
1/2 Complete
Not Started
Behind Schedule
One week behind schedule, manage completion within
the 2 weeks of available slack
D
Complete
2/3 Complete
Behind Schedule
One week behind schedule, as a critical path activity this
extends completion time of entire project by one week;
add resources to Activities G or H to reduce their durations
to compensate for the excessive time consumed by Activity D ;
as an alternative, split Activity G and begin work not dependent
upon Activity D immediately, or begin work with assumptions
of what the inputs or deliverables from Activity D will be
E
Complete
1/2 Complete
Behind Schedule
One week needed to complete Activity E, but there is no slack
left; add resources to quickly complete Activity E; this activity
is a predecessor to Activity G, add resources to Activity G to
reduce its duration to compensate for the excessive time
consumed by Activity E
F
Complete
Complete
On Schedule
No action required
G
Not Started
Not Started
On Schedule
No action required
H
Not Started
Not Started
On Schedule
No action required
I
1/4 Complete
Not Started
Behind Schedule
One week needed to complete Activity A, carefully manage
completion within the 1 week of available slack remaining
No action required
One week needed to complete Activity I, carefully manage
completion within the 1 week of available slack
Table 5 - Disc Brake Modification Project – 4 Week Status Report Recovery Actions
Change Management
Encountering unanticipated problems during project execution is a common occurrence in project
management. When problems arise, this is an opportunity for the project manager and members of the project
team to develop creative solutions or new approaches to move the project forward. This is done with a
determination to achieve the goals and objectives defined for the project despite barriers. However, frequently
student engineers make changes in an undisciplined way, reacting to a problem rather than in a more thoughtout manner that selects the best solution from a number of alternatives and document changes to make all team
members aware of the revised project plan.
It has already been seen that a project may need to be changed to compensate for delays or set-backs during
execution. However, at times it may not be possible, or even desirable, to preserve the original plan; a
modified or new project plan may be the best alternative. Typically this results in new activities, a new time
schedule, or a re-working of project scope in which the specifications or goals and objectives of the project are
modified. When circumstances or new knowledge acquired dictate a significant modification to the project
plan, to maintain discipline during project execution, these changes must be approved using a “change
management process” before including them in the “plan of record”.
Change management is a simple process that ensures that all project team members affected are notified that
unanticipated circumstances or new information obtained during project execution required that the project
scope or plan be modified. They are informed of the approved changes and everyone’s work is aligned with
the revised “plan of record”.
172
© 2014 SAE International
Rev. 2 - October 15, 2014
The change management process also serves as a way to control “scope creep”, the tendency for a project to
extend beyond its initial boundaries as project team members succumb to pressure, either self-imposed or
from external sources, and attempt to deliver more than originally planned. Only work approved through the
change management process is authorized; resources are not to be applied to any other efforts.
Figure 7 - The Project “Change Management Process”
A basic change management system is shown schematically in Figure 7. When the need for a major change is
discovered by any team member, a change request is submitted to the project manager. This request briefly
describes the change and the reason it is necessary. Also it states if the change must be made immediately or if
it less urgent and can be bundled with other changes for implementation at a set time in the future.
In response to the change request, the project manager calls a meeting with all affected members of the project
team to determine the impact of the change on the current plan, identify other alternatives for addressing the
problem identified, and assess the possibility of re-directing resources and changing current schedule
commitment to accommodate the change.
After obtaining agreement with the project team leaders on the best approach to follow, the project manager
approves the change for implementation. A revised project plan is created and instructions are given for
updating engineering drawings so that they will accurately reflect what is being constructed under this version
of the project plan. All members of the project team are notified by the project manager of the new “plan of
record” and all efforts are now directed toward completing this new plan.
The change management process adopted should not be cumbersome or time consuming. But, it should help
maintain discipline during project execution. When project teams are driving hard to complete the project, it is
easy for a chaotic environment to develop. Under such conditions team members may be uncertain about the
plan being followed and documentation gradually “drifts from reality”, not accurately reflecting the end
product actually produced. The time spent using a well-designed change management process will be a
fraction of the time wasted in a poorly managed, undisciplined environment in which team members react to
situations rather than proceed in an orderly way to achieve the project goals.
173
© 2014 SAE International
Rev. 2 - October 15, 2014